Beruflich Dokumente
Kultur Dokumente
Service Manual
580T / 580ST
590ST / 695ST
580T
580ST
590ST
695ST
Backhoe Loaders
Backhoe Loaders
Print No. 84428671A
Service Manual
Copyright
TO THE READER
This manual has been printed for a skilful engineer to supply necessary technical information to
carry out service operations on this machine.
Carefully read this manual to collect correct information relevant to repair procedures.
REFERENCES
Beyond this Service Manual, also refer to the
documents listed below:
- Operators Manual
- Service Parts Catalogue
SERVICE MANUAL
The Service Manual consists of two volumes:
- 580T - 580ST - 590ST - 695ST
Service Manual for Backhoe loader
- 580T - 580ST - 590ST - 695ST
Service Manual for Engine
VOLUME
MACHINE TYPE
PRINT NUMBER
84428671A
87659057A
Copyright
PREVENT ACCIDENTS
The majority of accidents and injuries which occur in the workshop, at the worksite 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.
WARNING
Before carrying out any maintenance operation, adjustment and or repair on machines equipped with attachments, controlled hydraulically or mechanically, make sure that the attachment is lowered and safely set on
the ground. 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.
All rights reserved. Reproduction of text or illustrations, in whole or in part, is strictly prohibited.
Copyright
580ST
590ST
695ST
Powershuttle
Sideshift stabilizers
Center pivot stabilizers
Rops
2WD
/
/
Cab
4WD
4WS
Pilot control
Mechanical control
Engine Iveco 72 kW - 97 HP model
F4GE9484C*601 (mechanical)
Engine Iveco 72 kW - 97 HP model
F4HE0484G*J102 (electronic)
Copyright
Copyright
INDEX
SECTION 00 - SAFETY RULES
FOREWORD..................................................................................................................................................... 4
SAFETY INSTRUCTIONS ................................................................................................................................ 6
PREVENTION OF FIRE OR EXPLOSIONS..................................................................................................... 8
PREVENTION OF BURNS ............................................................................................................................... 9
PRECAUTIONS FOR WASTE DISPOSAL..................................................................................................... 10
SECTION 01 - MAINTENANCE
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INDEX
SECTION 21 - TRANSMISSION
POWERSHUTTLE TRANSMISSION ................................................................................................................ 3
TECHNICAL SPECIFICATIONS.................................................................................................................. 4
CONTROLS ................................................................................................................................................. 9
LUBRICATION ........................................................................................................................................... 13
GREASING ................................................................................................................................................ 16
REMOVAL FROM MACHINE .................................................................................................................... 18
DISASSEMBLY AND ASSEMBLY............................................................................................................. 19
TROUBLESHOOTING ............................................................................................................................. 144
REPAIR TIMES........................................................................................................................................ 148
SPECIAL TOOLS..................................................................................................................................... 149
POWERSHIFT TRANSMISSION .................................................................................................................. 150
TECHNICAL SPECIFICATIONS.............................................................................................................. 150
CONTROLS ............................................................................................................................................. 161
LUBRICATION ......................................................................................................................................... 163
GREASING .............................................................................................................................................. 165
REMOVAL FROM MACHINE .................................................................................................................. 166
DISASSEMBLY AND ASSEMBLY........................................................................................................... 167
TROUBLESHOOTING ............................................................................................................................. 331
REPAIR TIMES........................................................................................................................................ 335
SPECIAL TOOLS..................................................................................................................................... 336
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INDEX
SECTION 27 - REAR AXLE
2WS REAR AXLE (580T - 580ST).................................................................................................................... 3
TECHNICAL SPECIFICATIONS.................................................................................................................. 3
LUBRICATION AND GREASING ................................................................................................................ 5
REMOVAL FROM MACHINE ...................................................................................................................... 7
DISASSEMBLY AND ASSEMBLY............................................................................................................... 8
TROUBLESHOOTING............................................................................................................................... 61
REPAIR TIMES.......................................................................................................................................... 67
SPECIAL TOOLS....................................................................................................................................... 68
2WS REAR AXLE (590ST) ............................................................................................................................. 69
TECHNICAL SPECIFICATIONS................................................................................................................ 69
LUBRICATION AND GREASING .............................................................................................................. 71
REMOVAL FROM MACHINE .................................................................................................................... 73
DISASSEMBLY AND ASSEMBLY............................................................................................................. 74
TROUBLESHOOTING............................................................................................................................. 127
REPAIR TIMES........................................................................................................................................ 133
SPECIAL TOOLS..................................................................................................................................... 134
4WS REAR AXLE (695ST) ........................................................................................................................... 135
TECHNICAL SPECIFICATIONS.............................................................................................................. 135
LUBRICATION AND GREASING ............................................................................................................ 138
REMOVAL FROM MACHINE .................................................................................................................. 140
DISASSEMBLY AND ASSEMBLY........................................................................................................... 141
TROUBLESHOOTING............................................................................................................................. 219
REPAIR TIMES........................................................................................................................................ 225
SPECIAL TOOLS..................................................................................................................................... 227
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INDEX
SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC DIAGRAMS ................................................................................................................................. 3
HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS ....................................................... 3
HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS .................................................................... 9
HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS ..................................................... 13
HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS .................................................................. 15
HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS .......................................................... 17
HYDRAULIC PUMP ........................................................................................................................................ 19
HYDRAULIC FIXED-FLOW-RATE GEAR PUMP...................................................................................... 19
HYDRAULIC VARIABLE-FLOW-RATE PISTON PUMP............................................................................ 30
CONTROL VALVES........................................................................................................................................ 44
LOADER CONTROL VALVE ..................................................................................................................... 53
BACKHOE ATTACHMENT CONTROL VALVE......................................................................................... 57
RELIEF VALVES........................................................................................................................................ 69
BACKHOE ATTACHMENT CONTROL VALVE PILOT SOLENOID VALVE .................................................. 78
ACCUMULATOR GLIDE RIDE PARKER ..................................................................................................... 81
TECHNICAL SPECIFICATIONS................................................................................................................ 81
MAINTENANCE ......................................................................................................................................... 81
SAFETY ..................................................................................................................................................... 81
CHECKING AND ADJUSTING THE PRECHARGE PRESSURE ............................................................. 82
HYDRAULIC SWING SYSTEM ...................................................................................................................... 84
OPERATION .............................................................................................................................................. 84
HYDRAULIC CYLINDERS.............................................................................................................................. 87
LOADER ATTACHMENT BOOM CYLINDER............................................................................................ 88
LOADER BUCKET CYLINDER.................................................................................................................. 93
4X1 LOADER BUCKET CYLINDER .......................................................................................................... 97
BACKHOE BOOM CYLINDER ................................................................................................................ 100
BACKHOE ATTACHMENT DIPPER CYLINDER .................................................................................... 104
BACKHOE BUCKET CYLINDER............................................................................................................. 108
TELESCOPIC CYLINDER ....................................................................................................................... 112
STABILIZER CYLINDER - CENTER PIVOT (695ST).............................................................................. 115
STABILIZER CYLINDER - SIDESHIFT ................................................................................................... 119
SWING CYLINDER.................................................................................................................................. 123
BACKHOE ATTACHMENT LOCK CYLINDER - SIDESHIFT .................................................................. 127
SPECIAL TOOLS..................................................................................................................................... 128
HYDRAULIC CONTROL LEVERS................................................................................................................ 129
TECHNICAL SPECIFICATIONS.............................................................................................................. 129
CONTROLS AND OPERATION .............................................................................................................. 130
COMPONENTS ....................................................................................................................................... 131
DISASSEMBLY AND ASSEMBLY........................................................................................................... 133
CONTROL LEVER VALVE ...................................................................................................................... 136
TROUBLESHOOTING .................................................................................................................................. 138
PRELIMINARY CHECKS......................................................................................................................... 138
TROUBLESHOOTING (WITH REXROTH CONTROL VALVES).......................................................... 139
SWING ..................................................................................................................................................... 141
HYDRAULIC PUMP ................................................................................................................................. 142
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INDEX
SECTION 39 - CHASSIS
DESCRIPTION ................................................................................................................................................. 3
REMOVAL AND INSTALLATION OF COMPONENTS .................................................................................... 5
COMPONENTS WITHIN THE CHASSIS .................................................................................................... 5
COMPONENTS OF THE LOWER PART OF THE CHASSIS ..................................................................... 6
COMPONENTS ATTACHED OUTSIDE THE CHASSIS........................................................................... 10
COMPONENTS OF THE UPPER PART ................................................................................................... 11
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INDEX
SECTION 55 - ELECTRIC SYSTEM
ELECTRIC DIAGRAMS .................................................................................................................................... 3
ELECTRIC DIAGRAMS - POWERSHUTTLE ROPS (580T mechanical engine) ........................................ 3
ELECTRIC DIAGRAMS - POWERSHUTTLE CAB (580T mechanical engine) ......................................... 18
ELECTRIC DIAGRAMS - POWERSHUTTLE CAB (580ST - 590ST electronic engine)............................ 36
ELECTRIC DIAGRAMS - POWERSHIFT CAB (2WS) .............................................................................. 54
ELECTRIC DIAGRAMS - POWERSHIFT CAB (4WS) .............................................................................. 73
CONTROLS AND INSTRUMENTS................................................................................................................. 92
FRONT CONTROL PANELS (580T - 580ST - 590ST).............................................................................. 92
FRONT CONTROL PANELS (695ST) ....................................................................................................... 94
CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580T mechanical engine).............................. 96
CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580ST - 590ST - 695ST electronic engine) ..........98
SIDE INSTRUMENT CLUSTER (580T)................................................................................................... 100
SIDE INSTRUMENT CLUSTER (580ST - 590ST - 695ST)..................................................................... 102
ANTI-START SYSTEM ............................................................................................................................ 104
DIAGNOSTIC DISPLAY (580ST - 590ST - 695ST) ...................................................................................... 105
SYMBOLS................................................................................................................................................ 107
SETUP MENU.......................................................................................................................................... 108
PROCEDURE ABOUT SELF TEST......................................................................................................... 109
ON BOARD ERROR CODE RETRIEVAL................................................................................................ 110
BACKLIGHTING AND DIMMING............................................................................................................. 111
WORK HOURS ........................................................................................................................................ 112
OPERATION ............................................................................................................................................ 113
WARNING SYSTEM ................................................................................................................................ 117
MAINTENANCE ....................................................................................................................................... 118
WARNING MESSAGES........................................................................................................................... 119
STARTING SYSTEM .................................................................................................................................... 125
OPERATION ............................................................................................................................................ 125
STARTER MOTOR .................................................................................................................................. 128
TROUBLESHOOTING ............................................................................................................................. 133
ALTERNATOR .............................................................................................................................................. 135
TECHNICAL SPECIFICATIONS.............................................................................................................. 135
OPERATION ............................................................................................................................................ 136
TROUBLESHOOTING ............................................................................................................................. 137
BATTERY...................................................................................................................................................... 138
TECHNICAL SPECIFICATIONS.............................................................................................................. 138
OPERATION ............................................................................................................................................ 138
REPLACEMENT ...................................................................................................................................... 139
CHARGE AND ELECTROLYTE LEVEL CHECK .................................................................................... 140
CONNECTING A BOOSTER BATTERY ................................................................................................. 141
BATTERY MASTER SWITCH ................................................................................................................. 141
TROUBLESHOOTING .................................................................................................................................. 142
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INDEX
SECTION 82 - LOADER ATTACHMENT
LOADER ATTACHMENT CONTROLS............................................................................................................. 3
LOADER ATTACHMENT OPERATION ...................................................................................................... 3
4x1 LOADER BUCKET CONTROL (Optional) ............................................................................................ 6
LOADER ATTACHMENT CONTROL LOCK (Specific to certain countries)................................................ 7
BUCKET SELF-LEVELLING............................................................................................................................. 8
LOADER ATTACHMENT SAFETY STRUT...................................................................................................... 9
LOADER ATTACHMENT SAFETY STRUT (2WS) ..................................................................................... 9
LOADER ATTACHMENT SAFETY STRUT (4WS) ................................................................................... 10
REMOVAL AND INSTALLATION OF LOADER BUCKET.............................................................................. 11
STANDARD LOADER BUCKET................................................................................................................ 11
LOADER BUCKET WITH FORKS (Optional) ............................................................................................ 12
BUCKET TEETH REPLACEMENT............................................................................................................ 13
LOADER REMOVAL....................................................................................................................................... 14
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INDEX
Copyright
580T
580ST
590ST
695ST
Copyright
2
Copyright
SECTION 00 - SAFETY RULES
SAFETY INSTRUCTIONS
WARNING
This warning symbol points out important messages involving your safety.
Carefully read the safety rules contained herein
and follow advised precautions to avoid potential
hazards and to safeguard your safety and personal
integrity.
In this manual you will find this symbol together
with the following keywords:
WARNING
This symbol warns about the possibility of potential
damages to the machine that can involve the operators safety.
WARNING
With specific warnings about potential dangers for
the operators or other persons integrity directly or
indirectly involved.
The non-compliance with the warnings preceded by
the above-mentioned keywords (WARNING and
DANGER) can cause serious accidents or even the
death of the persons involved.
Moreover, in the present Manual, some instructions
are given with text in italics, preceded by the words
NOTE and CAUTION.
NOTE: it emphasizes and underlines to the operator
the correct technique or correct procedure to follow.
WARNING
This symbol warns about the possibility of potential
damages to the machine that can involve the operators safety.
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4
FOREWORD
Backhoe loaders 580T - 580ST - 590ST - 695ST
have been designed to perform most earth-moving
operations.
If you use this machine for duties involving the use
of attachments, accessories, or special tools, consult your Dealer to make sure that the adaptations or
modifications carried out are in conformity with the
machines technical specifications and with current
regulations on safety.
Any modifications or adaptations which are not
approved by the manufacturer may invalidate the
machines original conformity with safety requirements.
The machine must be used according to its intended
use, respecting the safety and precautionary rules
and strictly following the operating instructions.
Any functional disorders, especially those affecting
the safety of the machine, should therefore be rectified immediately.
DANGER
A different use of the excavator or of its working
equipment:
- for lifting or transporting persons;
- as a working platform;
- for lifting loads without the attachment being
approved for this purpose;
- for pulling loads;
- is considered unintended use.
Unintended use may cause injury or life-threatening
risks for the operator and for other persons.
The manufacturer/supplier cannot be held responsible for any damage resulting from unintended use.
The risk involved in such misuse lies entirely with
the user.
DANGER
It is absolutely forbidden to tamper with and/or
change the setting of any of the hydraulic system
valves to avoid damaging machine components,
with a consequent risk for personal safety.
The current Operators Manual is the users guide
for correct run-in, use and maintenance of the
machine.
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SECTION 00 - SAFETY RULES
Carefully read this Operators Manual and store it in
the cab for quick location and reference.
Instructions concerning safety, operation and maintenance have been developed to permit safe service and repair of this machine without any risk.
In the event of queries or suggestions relevant to
your machine do not hesitate to address to your
Dealer.
Dealers have qualified and trained personnel at disposal as well as Original Spares, means and equipment suitable to carry out all necessary
maintenance.
Any modifications or adaptations which are not approved by the manufacturer may invalidate the machines original conformity with safety requirements.
IMPORTANT: the engine and fuel system on your
machine are designed and built to government
emissions standards. Tampering by dealers, customers, operators and users is strictly prohibited by
law. Failure to comply with this prohibition could
result in government fines, rework charges, invalid
warranty, legal action and possible confiscation of
the machine until rework to original condition is
completed. Engine service and/or repairs must be
carried out by a certified technician only.
NOTE: each machine is supplied complete with a
copy of this Manual. Descriptions and illustrations
provided herein are not binding. The Manufacturer,
provided that the basic characteristics of machine
types described and shown in this Manual remain
the same, reserves the right to change components, parts and accessories supplied without any
commitment to timely update this publication; and
this any time it deems it convenient for improvement purposes or due to commercial or manufacturing requirements. For exact information, please
consult your Dealer or contact the Manufacturers
Branch Offices, who remain at your disposal for further help.
SPARE PARTS
The non-genuine spare parts have not been
checked and authorized by the Manufacturer.
The assembly and/or use of such products may
have negative effects on the machine design features and could impair its operation safety.
The Manufacturer is not liable for any damage
caused by non-genuine spare parts or accessories.
WARRANTY
This machine is under warranty according to the
regulations in force in Your Country and in compliance with the sales agreement drawn up with the
Dealer.
The warranty, however, expires if the operation and
maintenance instruction for this machine and contained in this manual, have not been followed.
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6
SAFETY INSTRUCTIONS
Carefully read the safety rules contained herein and
follow advised precautions to avoid potential hazards and to safeguard your safety and personal
integrity.
Your safety and that of the people around you
depends on you.
It is essential that you understand this manual for a
correct inspection, lubrication and repair of this
machine.
Read this manual carefully and check that:
- you understand fully the symbols on the controls
and the safety signs used in this manual and on
the machine;
- you understand fully the speed, stability, braking
and steering characteristics of the machine. If you
are in any doubt, consult your Dealer.
The safety messages in this section concern situations which may arise during normal machine operation, servicing and repair. These safety messages
also indicate the different ways of coping with these
situations. Other safety messages are used
throughout the manual to indicate specific dangers.
The information given in this chapter is a summary
of the basic rules to respect at all times and does
not exempt you from observing traffic regulations or
the requirements of insurance companies.
The presence of grease, oil, mud or (in winter) ice
on the steps and access handles can cause accidents. Make sure they are always clean.
When mounting or dismounting from the machine
always face the machine and use the steps and
access handles on the left-hand side of the
machine.
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SECTION 00 - SAFETY RULES
Wear close fitting clothing and safety equipment
appropriate for the job:
- safety helmet;
- safety shoes;
- heavy gloves;
- reflective clothing;
- wet weather clothing.
If the environment conditions make it necessary, the
following personal safety equipment should be at
hand:
- respirators (or dustproof masks);
- ear plugs or acoustic ears protections;
- goggles with lateral shield or masks for eyes protection.
Do not wear rings, wristwatches, jewels, unbuttoned
or flapping clothing such as ties, torn clothes,
scarves, open jackets or shirts with open zips which
could get caught into moving parts.
Any functional disorders, especially those affecting
the safety of the machine, should therefore be rectified immediately.
Make sure that you fully understand the symbols of
the safety decals applied on the machine. Make
sure that they are always clean and perfectly legible.
Be prepared for emergencies.
Always keep a first aid kit and a fire extinguisher
close at hand on the machine.
Make sure that the fire extinguisher is serviced in
accordance with the manufacturers instructions.
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8
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SECTION 00 - SAFETY RULES
PREVENTION OF BURNS
The battery electrolyte generates severe burns.
The battery contains sulphuric acid.
Avoid any contact with the skin, eyes or clothing.
Antidote:
- EXTERNAL: rinse well with water, removing any
soiled clothing.
- INTERNAL: avoid vomiting. Drink water to rinse
your mouth. Consult a doctor.
- EYES: rinse thoroughly with water for 15 minutes
and get prompt medical attention.
When the electrolyte of a battery is frozen, it can
explode if you attempt to charge the battery or if you
try to start the engine using a booster battery.
Always keep the battery charged to prevent the electrolyte freezing.
Batteries generate explosive gases.
Keep all flames, sparks and cigarettes away.
Provide good ventilation when changing a battery or
using a battery in an enclosed space.
Always protect your eyes when working near a battery.
Never touch the battery terminals with your hands.
This can induce a state of electrolysis and impair the
main organs of the body.
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Copyright
580T
580ST
590ST
695ST
SECTION 01 - MAINTENANCE
Copyright
2
SECTION 01 - MAINTENANCE
Copyright
SECTION 01 - MAINTENANCE
Do not carry out any service operation until you
have read and understood the instructions and
warnings given in this manual.
Observe the adjusting, maintenance and inspection
activities and intervals set out in the operating
instructions, including information on the replacement of parts and equipment as this service concerns exclusively the qualified personnel.
Wear safety equipment and suitable clothing to perform maintenance operations on the machine.
During maintenance operations, apply a warning
plate.
Always wear eye protection when using a tool which
might project metal particles. Use a hammer with a
soft face, such as copper, for pin assembly.
Incorrectly performed maintenance or adjustments
can cause serious injury. If you do not understand a
maintenance or adjustment procedure, consult your
Dealer.
Before performing any maintenance operation on
this machine, make sure it is in a safety condition.
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4
SECTION 01 - MAINTENANCE
Place some wedges under the wheels so as to prevent the machine from moving.
Unauthorized modifications of the machine can
cause serious injuries.
Do not carry out any modification on this machine
without obtaining prior authorization from your
Dealer.
Any modification carried out must be in conformity
with the machines technical specifications and must
conform to current safety regulations.
Do not carry out any welding operation on the
machine without prior authorization from your
Dealer.
Some of the machines components are subject to
type approvals. It is mandatory when replacing
those components to ensure that they are in conformity with regulations.
Hydraulic fluid or grease under pressure which penetrates the skin can cause serious injury.
Take the necessary safety precautions (protective
clothing and face and hand protection) to prevent all
such risks.
In addition, before handling these products, read the
manufacturers specific instructions for their use.
If hydraulic fluid penetrates the skin a doctor must
be called immediately.
When carrying out a welding operation on the
machine, as authorized by the manufacturer and in
accordance with his specifications, disconnect the
electric system by means of the battery master
switch, connect the welding set earth lead to the
component on which the welding is to be carried out
(never connect the ground lead to a hydraulic system component) and disconnect the electric cables
of the motor control unit (in case of electronic
motors).
A burst tyre can cause serious injury.
Regularly check the condition of tyres and always
observe the inflation pressures defined in accordance with the type of tyre and ground conditions.
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SECTION 01 - MAINTENANCE
When checking the tyre pressure or during an inflation operation, never stay in front of the tyre but
always keep to the tread side.
Always use an inflation cage when the wheel is
removed from the machine.
Keep all other persons away from the area.
Never weld near a tyre. It is essential to remove the
tyre before any welding operation.
Take the necessary safety measures to protect your
face when using compressed air.
The machines structure is in conformity with the
FOPS and ROPS protection standards.
Any modification (drilling, welding, etc.) may cause
that conformity to be invalidated.
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6
NOTE:
SECTION 01 - MAINTENANCE
Copyright
580T
580ST
590ST
695ST
SECTION 02 - TECHNICAL
SPECIFICATIONS
MODELS........................................................................................................................................................... 3
IDENTIFICATION OF MAIN COMPONENTS................................................................................................... 4
TECHNICAL SPECIFICATIONS....................................................................................................................... 6
DIESEL ENGINE ......................................................................................................................................... 6
TRANSMISSION.......................................................................................................................................... 9
AXLES ....................................................................................................................................................... 10
BRAKES .................................................................................................................................................... 11
STEERING................................................................................................................................................. 11
HYDRAULIC SYSTEM .............................................................................................................................. 12
FRONT COUNTERWEIGHT ..................................................................................................................... 12
NOISE AND VIBRATION LEVELS ............................................................................................................ 13
BUCKETS .................................................................................................................................................. 13
TYRES ....................................................................................................................................................... 14
DIMENSIONS AND PERFORMANCE............................................................................................................ 15
DIMENSIONS - 2WS SIDESHIFT ............................................................................................................. 15
DIMENSIONS - 4WS SIDESHIFT ............................................................................................................. 16
DIMENSIONS - 4WS CENTER PIVOT...................................................................................................... 17
LOADER ATTACHMENT PERFORMANCE.............................................................................................. 18
PERFORMANCE OF LOADER BUCKET WITH FORKS .......................................................................... 20
BACKHOE ATTACHMENT PERFORMANCE........................................................................................... 21
MAXIMUM LIFTING LOADS........................................................................................................................... 24
LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE .................................................................. 24
BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE ............................................................... 25
SUPPLY SUMMARY TABLE .......................................................................................................................... 26
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2
1.
Copyright
SECTION 02 - TECHNICAL SPECIFICATIONS
MODELS
580T
Powershift
580ST
590ST
695ST
Powershuttle
Stabilizer sideshift
Stabilizer center pivot
Rops
2WD
/
/
Cab
4WD
4WS
Pilot control
Mechanical control
Engine Iveco 72 kW - 97 HP model
F4GE9484C*601 (mechanical)
Engine Iveco 72 kW - 97 HP model
F4HE0484G*J102 (electronic)
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4
1. Loader bucket
2. Loader attachment
3. Front axle
4. Fuel tank
5. Rear axle
12. Stabilizers
6. Cab
7. Engine guard
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SECTION 02 - TECHNICAL SPECIFICATIONS
4WS
1. Loader bucket
2. Loader attachment
3. Front axle
4. Fuel tank
5. Rear axle
12. Stabilizers
6. Cab
7. Engine guard
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6
TECHNICAL SPECIFICATIONS
DIESEL ENGINE
72 kW - 97 HP ENGINE (580T)
Specifications (EEC 88/195) .................................................................................. 72 kW - 97 HP @ 2200 rpm
Model ...................................................................................................................................... F4GE9484C*601
Type ......................................................................................................................................diesel, mechanical
No. of cylinders ................................................................................................................................................ 4
Valves per cylinder ........................................................................................................................................... 2
Bore.............................................................................................................................................. 104 mm (4 in)
Stroke ........................................................................................................................................ 132 mm (5.2 in)
Displacement .................................................................................................................. 4485 cm3 (237.69 in3)
Compression ratio .................................................................................................................................... 17.5:1
Maximum torque (EC) ......................................................................................420 Nm (309 lbfft) @ 1250 rpm
Low idle speed at no load ........................................................................................................... 1000 50 rpm
High idle speed at no load (engine not installed) ........................................................................ 2430 50 rpm
High idle speed at no load (engine not installed on the vehicle) ................................................. 2380 60 rpm
Maximum speed at full load ................................................................................................................ 2200 rpm
Air intake ....................................................................................................TAA (turbocharged with aftercooler)
Supply
Type ............................................................................................................................................ direct injection
Injection pump ............................................................................................. BOSCH ROTARY VE 4/12 F1100L
Injection sequence ..................................................................................................................................1-3-4-2
Cold-start device .............................................................................................................grid heater (optional)
Cooling
Pump type ......................................................................................................................................... H2O pump
Pump drive ...........................................................................................................................................belt drive
Temperature switch (opening start) .......................................................................... 81 2 C (177.8 35.6 F)
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SECTION 02 - TECHNICAL SPECIFICATIONS
72 kW - 97 HP ENGINE (580ST)
Specifications (EEC 88/195) .................................................................................. 72 kW - 97 HP @ 2200 rpm
Model .................................................................................................................................... F4HE0484G*J102
Type .........................................................................................................................................diesel, electronic
No. of cylinders ................................................................................................................................................ 4
Valves per cylinder ........................................................................................................................................... 4
Bore ............................................................................................................................................. 104 mm (4 in)
Stroke........................................................................................................................................ 132 mm (5.2 in)
Displacement .................................................................................................................. 4485 cm3 (237.69 in3)
Compression ratio.................................................................................................................................... 17.5:1
Maximum torque (EC) ...................................................................................... 453 Nm (334 lbfft) @ 1400 rpm
Low idle speed at no load ........................................................................................................... 1000 50 rpm
High idle speed at no load (engine not installed) ........................................................................ 2430 50 rpm
High idle speed at no load (engine not installed on the vehicle) ................................................. 2380 60 rpm
Maximum speed at full load ................................................................................................................ 2200 rpm
Air intake ....................................................................................................TAA (turbocharged with aftercooler)
Supply
Type ........................................................................................................................high-pressure, common rail
Injection pump............................................................................................................ CP3 high-pressure pump
Control unit................................................................................................................................................EDC7
Injection sequence ..................................................................................................................................1-3-4-2
Cold-start device .............................................................................................................grid heater (optional)
Cooling
Pump type ......................................................................................................................................... H2O pump
Pump drive ...........................................................................................................................................belt drive
Temperature switch (opening start)......................................................................... 81 2 C (177.8 35.6 F)
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8
Supply
Type .........................................................................................................................high-pressure, common rail
Injection pump ............................................................................................................. CP3 high-pressure pump
Control unit.................................................................................................................................................EDC7
Injection sequence ...................................................................................................................................1-3-4-2
Cold-start device ..............................................................................................................grid heater (optional)
Cooling
Pump type .......................................................................................................................................... H2O pump
Pump drive ............................................................................................................................................belt drive
Temperature switch (opening start) .......................................................................... 81 2 C (177.8 35.6 F)
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SECTION 02 - TECHNICAL SPECIFICATIONS
TRANSMISSION
2WD/2WS TRANSMISSION - POWERSHUTTLE (580T)
Model ..................................................................................................................... CARRARO TLB1 MPB 2WD
Type (4x4) ..................................................................................................4 forward and 4 reverse travel gears
Torque converter ratio .................................................................................................................................. 2.38
Transmission ratios:
1st gear ......................................................................... forward travel 5.603:1
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10
AXLES
FRONT AXLES
2WD/2WS front axle (580T)
Model .......................................................................................................................................................... CNH
Type ....................................................................................................................................................... steering
4WD/2WS front axle (580ST - 590ST)
Model .......................................................................................................................................................... CNH
Type ....................................................................................................................................................... steering
4WD/4WS front axle (695ST)
Model ...................................................................................................................................... CARRARO 26.32
Type ....................................................................................................................................................... steering
REAR AXLES
2WS rear axle
Model (580T - 580ST) ............................................................................................................. CARRARO 28.44
Model (590ST) ........................................................................................................................ CARRARO 28.50
Type ............................................................................................................................................................. rigid
4WS rear axle (695ST)
Model ................................................................................................................................... CARRARO 26.32M
Type ....................................................................................................................................................... steering
Differential lock......................................................................................................................................... electric
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SECTION 02 - TECHNICAL SPECIFICATIONS
11
BRAKES
SERVICE BRAKES
2WS
Type .......................................................................................................wet multi-discs, 4 x axle (2 x half axle)
Braking surface ..................................................................................................................... 1236 cm2 (191 in2)
4WS
Type .......................................................................................................wet multi-discs, 6 x axle (3 x half axle)
Braking surface .................................................................................................................... 1092 cm2 (169 in2)
PARKING BRAKE
Type ....................................................................................................................................... manual, with lever
Maximum lever pull ....................................................................................................................1650 N (371 lbf)
Lever stroke ............................................................................................................................... 21 mm (0.87 in)
Maximum torque - POWERSHUTTLE ...............................................................................2000 Nm (1475 lbfft)
Maximum torque - POWERSHIFT ..................................................................................... 1500 Nm (1106 lbfft)
STEERING
2WS ............................................................................................................................................... 2 wheel steer
4WS ............................................................................................................................................... 4 wheel steer
System pressure .............................................................................................. 170 175 bar (2465 2538 psi)
POWER STEERING
2WS (with variable-flow-rate pump)
Model ......................................................................................................................... EATON P/N 403 -8754-04
Displacement ............................................................................................................. 160 cm3/rev (9.76 in3/rev)
Shock valve adjustment ......................................................................................................... 235 bar (3408 psi)
Load-sensing pressure relief valve adjustment...................................................................... 175 bar (2538 psi)
2WS (with gear pump)
Model ......................................................................................................................... EATON P/N 403 -8754-08
Displacement ............................................................................................................. 160 cm3/rev (9.76 in3/rev)
Shock valve adjustment ......................................................................................................... 235 bar (3408 psi)
Load-sensing pressure relief valve adjustment............................................................................................... No
4WS
Model ......................................................................................................................... EATON P/N 403 -7754-04
Displacement ............................................................................................................. 160 cm3/rev (9.76 in3/rev)
Shock valve adjustment ......................................................................................................... 235 bar (3408 psi)
Load-sensing pressure relief valve adjustment...................................................................... 175 bar (2538 psi)
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12
HYDRAULIC SYSTEM
GEAR PUMP
Pump 72 kW - 97 HP (580T - 580ST)
Model ...........................................................................................................CASAPPA KP 30.34 - 05 S6 - LMF
Type ....................................................................................................................................... double gear pump
Flow rate ..................................................................................... 35.427 + 35.427 cm3/rev (2.16 + 2.16 in3/rev)
Pump 82 kW - 110 HP (590ST - 695ST)
Model ...........................................................................................................CASAPPA KP 30.38 - 05 S6 - LMF
Type ....................................................................................................................................... double gear pump
Flow rate ..................................................................................... 40.258 + 35.427 cm3/rev (2.45 + 2.16 in3/rev)
VARIABLE-FLOW-RATE PUMP
Pump 72 kW - 97 HP (580ST)
Model ....................................................................................................................... DANFOSS J71C Series 45
Type ......................................................................................................................................... with axial pistons
Flow rate ...................................................................................................................... 71 cm3/rev (4.33 in3/rev)
Pump 82 kW - 110 HP (590ST - 695ST)
Model ....................................................................................................................... DANFOSS J75C Series 45
Type ......................................................................................................................................... with axial pistons
Flow rate ...................................................................................................................... 75 cm3/rev (4.57 in3/rev)
FRONT COUNTERWEIGHT
COUNTERWEIGHT - 2WS
Standard ...................................................................................................................................... 159 kg (350 lb)
Medium ....................................................................................................................................... 330 kg (727 lb)
COUNTERWEIGHT - 4WS
Standard ...................................................................................................................................... 160 kg (352 lb)
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SECTION 02 - TECHNICAL SPECIFICATIONS
13
BUCKETS
LOADER BUCKETS
2WS
4WS
Type
1 m3 (35.3 ft3)
standard
4x1
Heaped capacity
Width
Weight
Heaped capacity
Width
Weight
BACKHOE BUCKETS
Type
300 (11.81)
89 (196)
400 (15.75)
104 (229)
450 (17.71)
112 (247)
600 (23.62)
130 (286)
750 (29.53)
151 (333)
900 (35.43)
171 (377)
406 (15.98)
139 (306)
457 (17.9)
149 (328)
610 (24)
176 (388)
914 (35.9)
228 (503)
Normal operation
Heavy Duty
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14
TYRES
TYRE TYPES
Tyres - 2WS
Front tyres
Rear tyres
11L-16 F3 12PR
18.4-26 R4 12PR
11L-16 F3 12PR
16.9-28 R4 12PR
12.5/80 - 18 L3 10PR
18.4-26 R4 10PR
12.5/80 - 18 L3 10PR
16.9-28 R4 10PR
2WD
4WD
Tyres - 4WS
Front and rear tyres
16.9/24 R4 12PR
16.9/28 R4 12PR
440/80 R28 IT520
440/80 R28 IT530
NUT TORQUES
Front nuts (2WS) ....................................................................................................................330 Nm (243 lbfft)
Rear nuts (2WS) ....................................................................................................................540 Nm (398 lbfft)
Front and rear nuts (4WS) .....................................................................................................700 Nm (516 lbfft)
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SECTION 02 - TECHNICAL SPECIFICATIONS
15
Wheel base
Stabilizer width
Cab height
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16
Wheel base
Stabilizer width
Cab height
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SECTION 02 - TECHNICAL SPECIFICATIONS
17
Wheel base
2380 mm - 2580 mm
(93.70 in - 101.57 in)
Cab height
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18
Maximum height/dimensions
Digging depth
2625 mm (103.35)
45
Dumping angle
45
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SECTION 02 - TECHNICAL SPECIFICATIONS
19
695ST
Maximum height/dimensions
Digging depth
45
Dumping angle
45
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20
695ST
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SECTION 02 - TECHNICAL SPECIFICATIONS
21
Telescopic dipper
extended
200
195
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695ST SIDESHIFT
Telescopic dipper
extended
198
195
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SECTION 02 - TECHNICAL SPECIFICATIONS
23
Telescopic dipper
extended
198
195
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4WS
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SECTION 02 - TECHNICAL SPECIFICATIONS
BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE
2WS (580T - 580ST)
2WS (590ST)
4WS (695ST)
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26
CASE
Specifications
INTERNATIONAL
Specifications
MODELS
QUANTITY
Litres
Gal
14
12.8
3.70
3.40
MS 1121
MS 1710
ASTM D6210
ALL
24
6.30
MAT 3525
2WS
4WS
140
118
36.90
31.10
ISO VG 46
DIN 51524 - part II
2WS
4WS
140
118
36.90
31.10
POWERSHUTTLE
TRANSMISSION
Akcela Hy-tran Ultra
2WD
4WD
18.5
20.8
4.07
4.57
ALL
20.8
4.57
2WD
0.2
0.10
Differential
6.5
1.70
Wheel
reduction
gear (each)
0.7
0.20
Differential
10.5
2.80
1.3
0.34
15.5
3.41
17
3.74
Differential
11
2.90
1.3
0.34
2WS
4WS
145
124
38.20
32.70
COOLING SYSTEM
Akcela Premium Anti-freeze
antifreeze 50% water 50%
HYDRAULIC SYSTEM
Akcela Nexplore
MS1209
POWERSHIFT TRANSMISSION
Akcela Hy-tran Ultra
FRONT AXLE (2WS)
Akcela Transaxle fluid 80W -140
MS1317
4WD
Differential 580T-580ST
590ST
251H EP
NLGI 2
ALL
As required
TELESCOPIC DIPPER
Akcela Moly Grease
251 H EP-M
NLGI 2
ALL
As required
ALL
240
AIR CONDITIONING
COMPRESSOR
PAG SP 20 oil
cm
14.6
in 3
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580T
580ST
590ST
695ST
SECTION 21 - TRANSMISSION
POWERSHUTTLE TRANSMISSION................................................................................................................ 3
TECHNICAL SPECIFICATIONS.................................................................................................................. 4
CONTROLS ................................................................................................................................................. 9
LUBRICATION........................................................................................................................................... 13
GREASING ................................................................................................................................................ 16
REMOVAL FROM MACHINE .................................................................................................................... 18
DISASSEMBLY AND ASSEMBLY............................................................................................................. 19
TROUBLESHOOTING............................................................................................................................. 144
REPAIR TIMES........................................................................................................................................ 148
SPECIAL TOOLS..................................................................................................................................... 149
POWERSHIFT TRANSMISSION.................................................................................................................. 150
TECHNICAL SPECIFICATIONS.............................................................................................................. 150
CONTROLS ............................................................................................................................................. 161
LUBRICATION......................................................................................................................................... 163
GREASING .............................................................................................................................................. 165
REMOVAL FROM MACHINE .................................................................................................................. 166
DISASSEMBLY AND ASSEMBLY........................................................................................................... 167
TROUBLESHOOTING............................................................................................................................. 331
REPAIR TIMES........................................................................................................................................ 335
SPECIAL TOOLS..................................................................................................................................... 336
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
POWERSHUTTLE TRANSMISSION
This transmission is used on powershuttle backhoe
loader models 580T - 580ST - 590ST.
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SECTION 21 - TRANSMISSION
TECHNICAL SPECIFICATIONS
2WD/2WS TRANSMISSION - POWERSHUTTLE (580T)
Model ..................................................................................................................... CARRARO TLB1 MPB 2WD
Type (4x4) ................................................................................................. 4 forward and 4 reverse travel gears
Torque converter ratio .................................................................................................................................. 2.38
Transmission ratios:
1st gear .........................................................................forward travel 5.603:1
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SECTION 21 - TRANSMISSION
DIMENSIONS
2WD
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6
4WD
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
PORTS
2WD
Ref.
Dimension
1 7/8 - 14 UNF
2 7/8 - 14 UNF
3 1/2 - 14 UNF
4
5
Use
Oil inlet from cooler
Oil outlet to cooler
Transmission temperature switch
Oil drain plug
Notes - Miscellaneous
8
9
10
11
12
13
1/8 - 28 BSP ISO 228 Forward gear pressure check port 0.3 bar (4.3 psi) = maximum pressure in neutral
position
11 + 13 bar (159 + 188 psi)
1/8 - 28 BSP ISO 228 Reverse gear pressure check port 0.3 bar (4.3 psi) (4.3 psi) = maximum pressure
in neutral position
11 + 13 bar (159 + 188 psi)
Forward / reverse gear clutch
1/8 - 28 BSP ISO 228
0.3 bar (4.3 psi) = maximum pressure in neutral
pressure check port
position
1/8 - 28 BSP ISO 228 Converter pressure check port
0.5 + 0.9 bar (7.3 + 13 psi)
9/16 - 18 UNF
Oil inlet / outlet for differential lock
13 bar (188 psi) at 900 rpm
9/16 - 18 UNF
Brake oil outlet / inlet
14.5 bar (210 psi) at 2200 rpm
9/16 - 18 UNF
Oil inlet from the brake
Oil inlet from service pump to
9/16 - 18 UNF
Brake pressure switch = 10 1 bar (145 14 psi)
brake release
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SECTION 21 - TRANSMISSION
4WD
Ref.
Dimension
1 7/8 - 14 UNF
2 7/8 - 14 UNF
3 1/2 - 14 UNF
4
5
Use
Oil inlet from cooler
Oil outlet to cooler
Transmission temperature switch
Oil drain plug
Notes - Miscellaneous
8
9
10
11
12
13
14
1/8 - 28 BSP ISO 228 Forward gear pressure check port 0.3 bar (4.3 psi) = maximum pressure in neutral
position
11 + 13 bar (159 + 188 psi)
1/8 - 28 BSP ISO 228 Reverse gear pressure check port 0.3 bar (4.3 psi) = maximum pressure in neutral
position
11 + 13 bar (159 + 188 psi)
Forward / reverse gear pressure
1/8 - 28 BSP ISO 228
0.3 bar (4.3 psi) = maximum pressure in neutral
check port
position
1/8 - 28 BSP ISO 228 Converter pressure check port
0.5 + 0.9 bar (7.3 + 13 psi)
9/16 - 18 UNF
Oil inlet / outlet for differential lock
13 bar (188 psi) at 900 rpm
9/16 - 18 UNF
Brake oil outlet / inlet
14.5 bar (210 psi) at 2200 rpm
9/16 - 18 UNF
Oil inlet from the brake
Oil inlet from service pump to
9/16 - 18 UNF
Brake pressure switch = 10 1 bar (145 14 psi)
brake release
13 + 14 bar (188 + 203 psi) at 900 rpm
4WD pressure check port
13 + 15.5 bar (188 + 225 psi) at 2200 rpm
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SECTION 21 - TRANSMISSION
CONTROLS
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SECTION 21 - TRANSMISSION
WARNING
Always apply the parking brake whenever the
machine is parked as the machine is free to roll
even though the transmission gearshift lever and
power reversing lever may be In Gear and the
engine is turned OFF.
GEARSHIFT LEVER
The gearshift lever (1) is used to select any of the 4
gear ratios.
The transmission disconnect button (2) is
depressed and held as the lever is shifted from one
gear to another. The button is then released to reestablish the power of transmission drive.
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SECTION 21 - TRANSMISSION
IMPORTANT: when operating at low environmental
temperatures with cold transmission oil, allow the oil
to warm up before attempting to shift the powershuttle lever. The transmission can be shifted normally
after the oil warms up.
IMPORTANT: the horn will sound if the powershuttle
lever is operated with the parking brake engaged.
IMPORTANT: The powershuttle lever can be activated with any engine speed.
As a safety and precautionary measure, the engine
must run at approximately 1200 rpm.
This action is easily controlled by means of the foot
accelerator to control engine and ground speed.
TRANSMISSION DISCONNECTION
The 4x4 transmission provides for easy upward and
downward gear ratio changes on the move.
However, as a clutch is not used between the
engine and transmission, the power flow from the
engine to the transmission must be interrupted to
shift from one gear ratio to another. This is accomplished by means of a transmission disconnect
(dump) button.
The finger operated button (2) on the main gearshift
lever knob (1) is easy to operate.
WARNING
Do not use the disconnect switch control down hill,
because excessive speed may cause loss of control, personal injury or the failure of transmission.
To make upward gear ratio changes, simply depress
and hold button (2) on the gearshift lever (1), while
shifting the same from one gear ratio to another.
When the desired gear ratio has been selected
release the button and allow the unit to gain engine
speed and ground speed. If another higher ratio is
required repeat the procedure.
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
LUBRICATION
2WD
4WD
13
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SECTION 21 - TRANSMISSION
LEVEL CHECK
The oil level check should be carried out with the
engine running at low speed and at normal operating temperature.
Move the machine to a level and firm ground.
Raise the loader attachment and assemble the
safety support strut.
Place the backhoe attachment in the road travel
position.
Place the direction-of-travel lever and gearshift
lever in neutral position.
Immobilize the machine by means of the parking
brake.
Open and raise the engine guard and lock it in
opened position by means of the safety lock on the
left-hand gas spring.
Extract the dipstick (1), clean it with a clean cloth
and completely insert it into the tube, then take it out
again.
If the oil level is below the mini mark, top up.
Stop the engine.
Unlock the safety lock and close the engine guard.
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SECTION 21 - TRANSMISSION
OIL CHANGE
Move the machine to a level and firm ground.
Raise the loader attachment and assemble the
safety support strut.
Place the backhoe attachment in the road travel
position.
Place the direction-of-travel lever and gearshift lever
in neutral position.
Immobilize the machine by means of the parking
brake.
Stop the engine and remove the starter key.
Open and raise the engine guard and lock it in
opened position by means of the safety lock on the
left-hand gas spring.
Remove the dipstick (1).
NOTE: change the oil while the transmission is still
warm; the oil will flow more easily.
Place a container with suitable capacity under the
drain plug (2).
Unscrew and remove the drain plug.
Let the transmission oil drain.
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SECTION 21 - TRANSMISSION
GREASING
Tecnolube POLYMER 400 grease
Transmission oil
2WD - 4WD
*: no grease, no oil
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SECTION 21 - TRANSMISSION
ONLY 4WD
17
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SECTION 21 - TRANSMISSION
1. Transmission
2. Anti-vibration
13. Dipstick
5. Washer
15. Washer
7. Washer
18. Plate
9. Washer
17. Plate
20. Washer
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SECTION 21 - TRANSMISSION
DISASSEMBLY AND ASSEMBLY
Some of the following pictures could not exactly
show your transmission, but the procedure is correct.
TIGHTENING TORQUES AND APPLICATION OF SEALANTS / ADHESIVES
A. Loctite 510
B. Loctite 518
C. Loctite 638
D. Loctite 542
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Only 4WD
21
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SECTION 21 - TRANSMISSION
Disassembly
Remove the oil drain plug (5) and drain the oil from
the transmission.
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SECTION 21 - TRANSMISSION
Remove the oil filter (4) and the O-ring (3).
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Assembly
Assemble the plugs (13) and the breather (11).
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Assemble the plug (5).
Tighten to the prescribed torque of 30 Nm (22 lbfft).
27
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SECTION 21 - TRANSMISSION
OIL PUMP
Disassembly
Loosen and remove the screws (1).
Mark the oil pump position with respect to the bell
housing before loosening the screws.
Use two levers (A) to pull out the oil pump (2).
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SECTION 21 - TRANSMISSION
Remove the oil pump (2).
The pump seal ring can be damaged during this
operation.
WARNING
Do not disassemble the pump or its operation may
be compromised.
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SECTION 21 - TRANSMISSION
Assembly
Assemble the seal ring (4) onto the oil pump (2).
Use tool 380200218.
Lubricate the seal ring.
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SECTION 21 - TRANSMISSION
Lubricate the matching seat with the front half box.
Assemble the oil pump (2).
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SECTION 21 - TRANSMISSION
TUBES
Disassembly
Drain transmission oil.
Loosen and remove the screws (1) and (2).
Remove the tube (3).
Collect the gaskets (4).
Assembly
Assemble the tube (3) with the gaskets (4).
Screw in and tighten the screws (1) and (2) to the
prescribed torque of 40 Nm (30 lbfft).
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SECTION 21 - TRANSMISSION
HYDRAULIC CONTROL VALVE
Disassembly
Disconnect all electric connections.
Drain the transmission oil.
Loosen and remove the screws (13).
Remove the hydraulic control valve (53).
33
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Push piston (4) downwards and remove the snap
ring (3).
35
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SECTION 21 - TRANSMISSION
Remove the valve cover (34).
37
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Remove the plug (32) and the O-ring (31).
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Remove the O-ring (19).
Remove the solenoid valve coil (18) and the O-ring
(17).
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SECTION 21 - TRANSMISSION
Assembly
Assemble the O-rings (17).
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SECTION 21 - TRANSMISSION
Assemble the solenoid tube (24), the spring (23),
the piston (21) and the washer (22).
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Position the gasket (37).
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Assemble the spring (9).
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Assemble the hydraulic control valve (53).
Screw in and tighten the screws (13) to a tightening
torque of 15 24.2 Nm (11 17.9 lbfft).
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SECTION 21 - TRANSMISSION
Disassembly
Prior to disassembling the 4WD solenoid valve, disconnect all electric connections.
Drain the transmission oil.
Loosen and remove the screws (1).
Remove the solenoid body (2).
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SECTION 21 - TRANSMISSION
Remove the nut (8).
Remove the solenoid valve coil (7).
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SECTION 21 - TRANSMISSION
Assembly
Assemble valve (3).
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SECTION 21 - TRANSMISSION
Remove the solenoid body (2).
Screw in and tighten the screws (1) to a tightening
torque of 23 Nm (17 lbfft).
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SECTION 21 - TRANSMISSION
PARKING HANDBRAKE
Disassembly
Drain the transmission oil.
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SECTION 21 - TRANSMISSION
Loosen and remove the screws (5), (6) and (7).
Remove the brake (8) assembly.
Remove the O-ring (9) from the brake (8).
WARNING
The seal ring can be damaged.
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SECTION 21 - TRANSMISSION
Assembly
Assemble the hub (13).
Counterdisc number
3.6 0.05 mm
(0.14 0.002 in)
37.40 37.60 mm
(1.47 1.48 in)
0.65 mm
(0.02 in)
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SECTION 21 - TRANSMISSION
Assemble the counterdisc (12), the brake disc (11)
and the ring (10).
Repeat this operation until the brake disc kit is complete.
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2WD - TRANSMISSION BOX
Disassembly
Remove the snap ring (1).
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Loosen and remove the screws (2).
Remove the gearshift control assy (3) and the O-ring
(4).
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Remove the 2 balls (15).
Loosen and remove the screws (16) and the washers (17).
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SECTION 21 - TRANSMISSION
Take out the bearing (24) with tool 380200190.
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SECTION 21 - TRANSMISSION
Assembly
Push the secondary shaft toward the back of the
rear box, so that there is backlash between the
snap ring seat and the rear box.
Assemble the snap ring (20).
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SECTION 21 - TRANSMISSION
Lubricate and assemble the bearings (27) and (28).
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SECTION 21 - TRANSMISSION
Assemble the bearing (24) on the transmission
shaft PTO (21).
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Assemble the pins (10) to fasten retainers on the
gearbox pins and the dowel pins (11).
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SECTION 21 - TRANSMISSION
4WD - TRANSMISSION BOX
Disassembly
Remove the snap ring (1).
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SECTION 21 - TRANSMISSION
Remove cover (7).
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Remove the retainers (20).
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SECTION 21 - TRANSMISSION
Loosen and remove the screws (24) and the washers (25).
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SECTION 21 - TRANSMISSION
Remove transmission shaft PTO (29) by pushing
lightly on the opposite side.
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Remove the bearing (38).
Assembly
Push the secondary shaft toward the back of the
rear box, so that there is backlash between the
snap ring seat and the rear box.
Assemble the snap ring (28).
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SECTION 21 - TRANSMISSION
Screw in and tighten the screws (33) to a tightening
torque of 50 Nm (37 lbfft).
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SECTION 21 - TRANSMISSION
Assemble the washer (3).
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Assemble the snap ring (31).
To assemble the teflon seal ring (30) perform following operations by means of the listed tools in
sequence:
380200257 (without shim);
380200225;
380200214.
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Apply a thin film of sealant on the edge of the rear
cover (16).
Assemble the O-ring (17).
Do not grease the O-ring.
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SHAFTS A, D
Disassembly
Grab the shaft with the (A) pliers and pull out the
shaft assy (D).
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Shaft (A)
If necessary, remove the seal ring (1).
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90
Remove the spacer (4).
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Remove the pin (9).
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Mark the snap ring (11), the discs (18) and the
counterdiscs (17).
These marks will be used as a reference during
assembly.
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Loosen the knobs of the threaded bars to clear the
spring tension.
Remove the upper part of tool 380200215.
Remove the clutch piston (19) by blowing in compressed air through the delivery hole.
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Remove the bearing (24) and the thrust washer
(25).
For the disassembly of other parts, repeat the operations described previously.
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Verify the bore and the housing of the input shaft for
damage that will cause leakage during the assembly
of the clutch.
Check if the slots in the housing of the input shaft
are damaged by the tangs of the counterdiscs.
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Shaft (D)
Remove the bearing (16) from the shaft (D) by
means of a puller.
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Assembly
Shaft (A)
Assemble the seal ring (20) with the relevant O-ring
and the seal ring (21) with the relevant inner O-ring,
respectively in the outer and inner seat of the piston.
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Assemble the sleeve (5).
Lower the cover (13) and insert the snap ring (14)
by means of tool 380200215.
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Use 2 screwdrivers to position the disc kit.
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NOTE: for clarity of the seal ring installation procedure, the following photos do not show the disc kit,
gear, spacer, bearing, and snap ring installed on the
input shaft.
Insert the seal ring (1).
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Let tool 380200224 slide on the input shaft and
above the spacer.
The tool will stop in the correct position to install the
seal ring in the groove.
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Turn the shaft upside down to carry out the operations described previously.
Lubricate the thrust washer (25).
Assemble the thrust washer so that the notch in the
inner edge fits over the pin.
Make sure that the side with the oil grooves is
down.
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Assemble the snap rings and place the spacer in
the protection (tool 380001933).
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SECTION 21 - TRANSMISSION
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In order to insert the other 3 rings, repeat the operations described previously, by means of following
spacer rings:
380001933/3 for the 2nd ring;
380001933/2 for the 3rd ring;
380001933/1 for the 4th ring.
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SECTION 21 - TRANSMISSION
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Shaft (D)
Assemble the bearing (16) on shaft (D) by means of
tool 380200230.
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SHAFTS B, C
Disassembly
Remove the shafts (B) and (C).
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Remove the gearshift control yokes.
To remove the shaft (C) use tool 380200246.
Shaft (C)
By means of a puller remove the bearing (1).
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Remove the ring (5) from each side of the synchronizer assy.
The components of the synchronizer assy are serviced as a complete unit.
The synchronizer assy may be disassembled for
inspection and cleaning.
If some parts are damaged, replace the synchronizer assy.
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Remove the blocks (8), the balls (9), the springs
(10) and the synchronizer hub (11).
The synchronizer hub contains 3 blocks (8), 3 balls
(9) and 3 springs (10).
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Remove the spacer (21).
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SECTION 21 - TRANSMISSION
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Support the sleeve on blocks.
Push it down and, at the same time, extract the
detent devices of sleeve and hub.
Remove the sleeve (31).
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Only with 4WD models
Remove the snap ring (38).
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Shaft (B)
Use a puller to remove the inner ring of bearing
(39).
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Assembly
Shaft (C)
Only with 4WD models
Put the secondary shaft on the bench so that the
first-second gear end is up.
You can use a vice with soft jaws to hold the shaft in
position.
Install the snap ring (13).
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Assemble the 1st speed gear (37).
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Lubricate the sintered ring (25) and the steel ring
(24) with oil.
Assemble the sintered ring (25) and the steel ring
(24).
Install the top synchronizer ring on the synchronizer
assy.
Make sure that the teeth on the top synchronizer
ring are aligned with the teeth inside the sleeve.
Push the sleeve upwards until it engages with the
teeth on top of synchronizer ring.
To do this, you must use enough force to overcome
the strength of the detent springs and balls.
When the synchronizer ring and the sleeve are
engaged, the detent must hold the sleeve in this
position.
Push the sleeve back to neutral position, turn over
the synchronizer assy and repeat the procedure
with the lower synchronizer ring.
If the sleeve does not engage with the teeth or does
not hold the position to which it was shifted, the synchronizer assy is damaged or was not correctly
assembled.
Disassemble the synchronizer assy to find the problem.
Install the ring (22) so that the flat sides of the teeth
are directed upwards.
Assemble the 1st/2nd speed synchronizer (23).
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Use a thickness gauge.
0.05
0.1
0.3
(0.002) (0.004) (0.012)
0.5
(0.02)
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Use oil to lubricate the ring (5) and install it on each
side of the synchronizer assy. Install the top synchronizer ring on the synchronizer assy.
Make sure that the teeth on the top synchronizer
ring are aligned with the teeth inside the sleeve.
Push the sleeve upwards until it engages with the
teeth on top of synchronizer ring.
To do this, you must use enough force to overcome
the strength of the detent springs and balls.
When the synchronizer ring and the sleeve are
engaged, the detent must hold the sleeve in this
position.
Push the sleeve back to neutral position, turn over
the synchronizer assy and repeat the procedure
with the lower synchronizer ring.
If the sleeve does not engage with the teeth or does
not hold the position to which it was shifted, the synchronizer assy is damaged or was not correctly
assembled.
Disassemble the synchronizer assy to find the problem.
Assemble the 3rd/4th speed synchronizer assy (4)
on the shaft.
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WARNING
The shaft assemblies must be inserted with pins
and yokes.
Insert the pre-fitted yokes for 3rd and 4th speed and
for 1st and 2nd speed as shown.
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Position the assy with care, paying attention that the
ends of the yoke pins are correctly seated.
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4WD - E SHAFT
Disassembly
Remove the shaft (E).
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Remove the 4WD clutch gear (10).
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132
Remove the springs (4).
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Remove the 4WD clutch tube (7) from the front box.
If necessary, or if the tube is leaking or damaged,
replace the front box.
Assembly
Assemble and lubricate the O-rings (6) and (9).
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Assemble tool 380200225 on tool 380200207 and
slide the seal ring until it reaches the groove of the
shaft.
Remove tools 380200225 and 380200207 and the
spacer from the shaft.
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Assemble the bearing (11).
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SPEED CONTROLS
Disassembly
Loosen and remove the screws (1).
For the disassembly of the two half boxes it is necessary to remove the gearshift control assy.
Remove the gearshift control assy (2) and the O-ring
(3).
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Use proper pliers to release the catch on the collar
fastening the boot.
Remove the collar (4).
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Assembly
Apply grease to the ball of the gearshift lever.
Assemble the gearshift lever (6).
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Assemble and lubricate the O-ring (3) in the seat of
the cover flange.
Put the gearshift control assy behind the rear cover.
Screw in and tighten the screws (1) to a tightening
torque of 23 Nm (17 lbfft).
Insert the two pins (11) to lock the 3rd and 4th
speed control yoke (13) and the 1st and 2nd speed
control yoke (14).
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TROUBLESHOOTING
FAULT
The vehicle does not
move.
POSSIBLE CAUSE
ACTION
Damage to sensors.
Replace sensors.
Damaged/restricted filter.
Damaged converter.
Synchronizers damaged.
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FAULT
POSSIBLE CAUSE
The brake does not release.
145
ACTION
Check the general pressure of
transmission.
Check voltage.
Check the operation of the solenoid
valve.
Check the mounting of the brake
solenoid valve block after operating on
the brake.
After the above-described
verifications, disassemble the brake
cover and check the condition of the
parts for unlocking/locking the brake
(seal rings, belleville washers, brake
disc deformation, etc.).
Overheating.
Damaged converter.
Replace/repair.
Overheated solenoids/solenoid
valves.
Replace.
Damage to sensors.
Replace sensors.
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FAULT
Noise.
Irregular coupling.
POSSIBLE CAUSE
ACTION
Damaged converter.
Damaged converter.
Ventilation/Cavitation.
Damaged converter.
Overheating.
See overheating.
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FAULT
POSSIBLE CAUSE
Synchronizers damaged.
Synchronizers damaged.
ACTION
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REPAIR TIMES
The times are referred to average values of maintenance performed by skilled personnel in workshops
equipped with all necessary fixtures for a proper
execution of the required works.
The repair and/or replacement times are indicated in
minutes.
We assume that the transmission assy has already
been removed from the machine.
ASSY
OPERATION
TIME (minutes)
Oil pump
20
15
60
10
60
20
80
50
60
Overhauling of shaft A
150
120
60
Replacement of shaft B
60
Overhauling/replacement of shaft C
150
60
60
Overhauling/replacement of shaft E
100
Shaft E
70
70
Gear/sleeve replacement
90
20
40
Brake overhauling/replacement
40
Lines
Control valve
4WD solenoid valve
(only with 4WD models)
Transmission box
Shafts A and D
Shafts B and C
Gearshift control
Parking brake
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149
SPECIAL TOOLS
PN CNH
DESCRIPTION
USE
2WD 4WD
380002211
Handle
380200190
Buffer
380200197
Buffer
380200203
Buffer
380200207
Protection
380200208
Protection
380200213
Protection
380200214
Calibrator
380200215
Attachment
380200218
Buffer
380200224
380200225
Plunger
380001926
Protection
380200226
Buffer
380200230
Buffer
380001933
380001927
Calibrator
380001928
Plunger
380200246
Hook
380200257
Protection
380200258
Tool
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POWERSHIFT TRANSMISSION
This transmission is used on powershift backhoe
loader models 580ST - 590ST - 695ST.
TECHNICAL SPECIFICATIONS
4WD/2WS TRANSMISSION - POWERSHIFT (580ST - 590ST)
Model ..................................................................................................................... CARRARO TLB2 MPB 4WD
Type (4x4) ................................................................................................. 4 forward and 4 reverse travel gears
Torque converter ratio .................................................................................................................................. 2.38
Transmission ratios:
1st gear .........................................................................forward travel 5.533:1
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151
Diagram
A.
B.
C.
D.
E.
F.
G.
H.
PS.
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DIMENSIONS
2WS
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4WS
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HYDRAULIC DIAGRAM
2WS
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REF.
DESCRIPTION
NOTES
Suction filter
Pump
Filter
10 Nm (7.4 lbfft)
Torque converter
Oil cooler
Air breather
10
11
12
13
14
4WD clutch
15
HDL
16
17
18
19
20
21
22
23
24
25
26
27
28
Temperature thermostat
29
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4WS
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REF.
DESCRIPTION
NOTES
Suction filter
Pump
Spin-on filter
10 Nm (7.4 lbfft)
Torque converter
Oil cooler
Air breather
10
11
12
13
14
4WD clutch
15
HDL
16
17
18
19
20
21
22
23
24
25
26
27
28
Temperature thermostat
29
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159
PORTS
2WS
REF.
DIMENSION
USE
7/8 - 14 UNF
7/8 - 14 UNF
9/16 - 18 UNF
NOTES - MISCELLANEOUS
9/16 - 18 UNF
9/16 - 18 UNF
9/16 - 18 UNF
9/16 - 18 UNF
Lubrication pressure check port (from cooler) 1 5 bar (14.5 72.5 psi) forward/reverse gear
Oil outlet to brake tank
9/16 - 18 UNF
10
9/16 - 18 UNF
Oil return
11
9/16 - 18 UNF
12
9/16 - 18 UNF
13
1/8 - BSP
14
1/8 - BSP
15
1/8 - BSP
16
1/8 - BSP
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4WS
REF.
DIMENSION
USE
7/8 - 14 UNF
7/8 - 14 UNF
9/16 - 18 UNF
NOTES - MISCELLANEOUS
9/16 - 18 UNF
10
11
12
13
1/8 - BSP
14
1/8 - BSP
15
1/8 - BSP
16
1/8 - BSP
Lubrication pressure check port (from cooler) 1 5 bar (14.5 72.5 psi) forward/reverse gear
Oil outlet to brake tank
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161
CONTROLS
2. KICKDOWN SWITCH: if the machine is in second gear and it is necessary to shift to the first
gear to work with the loader attachment, activating the kickdown switch to a lower ration
allows the machine to instantly shift from second to first gear.
When the reverse travel is activated, transmission reverts to second gear.
3. TRANSMISSION DISCONNECT BUTTON (on
loader attachment control lever)
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1
TRANSMISSION DISCONNECTION
The disconnect feature is useful when loading, for
example; when pushing the loader into a pile and
you have sufficient dirt in the bucket press the disconnect switch (3) which disengages the transmission and allows the full power of the engine to be
directed to the hydraulic oil pump.
Disconnection is available in 1st and 2nd gear.
NOTE: transmission disconnection is selectable
when the machine speed is lower than 5 km/h, by
depressing the button on the loader lever, and
remains active until the switch is released.
2
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LUBRICATION
LEVEL CHECK
The oil level check should be carried out with the
engine running at low speed and at normal operating temperature.
Move the machine to a level and firm ground.
Raise the loader attachment and assemble the
safety support strut.
Place the backhoe attachment in the road travel
position.
Place the direction-of-travel lever and gearshift
lever in neutral position.
Immobilize the machine by means of the parking
brake.
Open and raise the engine guard and lock it in
opened position by means of the safety lock on the
left-hand gas spring.
Extract the dipstick (1), clean it with a clean cloth
and completely insert it into the hose, then take it
out again.
If the oil level is below the mini mark, top up.
Stop the engine.
Unlock the safety lock and close the engine guard.
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OIL CHANGE
Move the machine to a level and firm ground.
Raise the loader attachment and assemble the
safety support strut.
Place the backhoe attachment in the road travel
position.
Place the direction-of-travel lever and gearshift lever
in neutral position.
Immobilize the machine by means of the parking
brake.
Stop the engine and remove the starter key.
Open and raise the engine guard and lock it in
opened position by means of the safety lock on the
left-hand gas spring.
Remove the dipstick (1).
NOTE: change the oil while the transmission is still
warm; the oil will flow more easily.
Place a container with suitable capacity under the
drain plug (2).
Loosen and remove the drain plug (2).
Let the transmission oil drain.
oil
capacity
20.8
litres
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GREASING
Tecnolube POLYMER 400 grease
Transmission oil
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1. Transmission
2. Anti-vibration
13. Dipstick
5. Washer
15. Washer
7. Washer
18. Plate
9. Washer
10. M12 nut
11. M8 x 25 screw
[tightening torque 26 31 Nm (19 23 lbfft)]
17. Plate
20. Washer
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DISASSEMBLY AND ASSEMBLY
Some of the following pictures could not exactly
show your transmission, but the procedure is correct.
TIGHTENING TORQUES AND APPLICATION OF SEALANTS / ADHESIVES
A. Loctite 510
B. Loctite 542
C. Loctite 518
D. Loctite 638
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Only 4WS
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PLUGS AND FILTERS
Disassembly
Remove the oil drain plug (1) and drain the oil from
the transmission.
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Check the valve (8).
Clean the valve.
If necessary, replace the O-rings (9) and (10).
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Assembly
Assemble the revolution sensor (15).
Tighten to the prescribed torque of 50 Nm (37 lbfft).
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SECTION 21 - TRANSMISSION
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Assemble the O-ring (5) on the filter (4).
Insert the filter (4).
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OIL PUMP
Disassembly
Loosen and remove the screws (1).
Mark the oil pump position with respect to the bell
housing before loosening the screws.
Pull out the oil pump (2) by means of two levers (A).
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Remove the oil pump (2).
WARNING
The O-ring can be damaged.
WARNING
Do not disassemble the pump or its operation may
be compromised.
WARNING
The seal ring can be damaged.
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Assembly
Assemble the seal ring (4) onto the oil pump (2).
Use tool 380200218.
Lubricate the seal ring (4).
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Lubricate the matching seat with the front half box.
Assemble the oil pump (2).
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HYDRAULIC CONTROL VALVE
Disassembly
Disconnect cable (12).
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Drain the transmission oil.
Disconnect the electric connections.
Loosen all the fittings of the delivery pipes connected with the control valve (2).
Loosen and remove the screws (1).
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Pull out the valves (6), (7) and (8) with a screwdriver.
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Check the valve (9).
Clean the valve and, if necessary, replace the O-rings
(10) and (11).
Assembly
Clean the valve (9).
Assemble the O-rings (10) and (11).
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Assemble the gasket (3).
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HYDRAULIC SYSTEM LINES
Disassembly
Drain the transmission oil.
Remove the tube (1) (2nd gear).
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Remove the tube (2) (4th gear).
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Remove the tube (6) (lubrication).
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Assembly
Assemble the tube (7) (lubrication) by tightening the
fittings to the tightening torque of 30 Nm (22 lbfft).
Assemble the tube (5) (4WD) by tightening the fittings to the tightening torque of 30 Nm (22 lbfft).
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PARKING BRAKE
Disassembly
Remove the oil drain plug (T) and drain the oil from
the transmission.
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WARNING
The seal ring can be damaged.
Remove the plug (5).
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Remove the hub (13).
Only 4WS
Remove the brake and the disc kit.
Do not remove the plug (16).
Only 4WS
Remove the screw (17), the washer (18) and the
hub (19).
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Assembly
Assemble the hub (13).
Counterdisc number
3.6 0.05 mm
(0.14 0.002 in)
37.40 37.60 mm
(1.47 1.48 in)
0.65 mm
(0.02 in)
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Assemble the counterdisc (12), the brake disc (11)
and the ring (10).
Repeat this operation until the brake disc kit is complete.
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Only 4WS
Assemble the hub (19), the washer (18) and the
screw (17).
Tighten the screw (1) to a tightening torque of 139 Nm
(102.5 lbfft).
Only 4WS
Assemble the brake disc kit and the brake (8).
Tighten the screws (6) and (7) to a tightening
torque of 50 Nm (37 lbfft).
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TRANSMISSION BOX
Disassembly
Remove the snap ring (16).
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Remove the seal ring (5).
WARNING
The seal ring can be damaged.
Only 4WS
Loosen and remove the screw (A) and the washer
(B).
If necessary, replace the O-ring (E).
Remove the flange (D).
If necessary, replace the seal ring (G).
Loosen and remove the screws (C).
Remove the hub (F).
Unscrew and remove the screws (6) for flange fastening (7).
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Loosen and remove the screws (12) from the rear
(13) and the front half box (14).
WARNING
Do not lift the transmission shafts; the removal of
the shafts from their housings can damage the seal
rings.
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Assembly
Clean the edge of the rear half box.
Carefully verify the box and its inner components for
the possible presence of debris (dirt, filings or
burrs).
Thoroughly clean all possible dirt.
WARNING
Only after a careful inspection of the whole transmission, proceed with the re-assembly.
Remove the old sealant from the mating surface of
the rear half box by means of a proper scraper.
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We suggest the use of a sealant solvent.
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Place the 4 O-rings (15) into their seats with a
buffer.
Tighten the screws (12) to the rear half box (13) and
to the front half box (14).
Tighten the screws (12) to a tightening torque of
50 Nm (37 lbfft).
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Assemble the bearing (11) on the transmission shaft
PTO (8).
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WARNING
During flange assembly, the 2 holes for the oil passage (P) should coincide.
Only 4WS
Assemble the hub (F).
Screw in and tighten the screws (C) to the tightening torque of 50 Nm (37 lbfft).
Assemble the seal ring (G) by means of tool
380200226.
Assemble O-ring (E).
Assemble the flange (D).
Place the washer (B), screw in and tighten the screw
(A) to the tightening torque of 139 Nm (102.5 lbfft).
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A, D SHAFTS
Disassembly
Grab the shaft with the (A) pliers and pull out the
shaft assy (D).
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Shaft (A)
If necessary, remove the seal ring (1).
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Remove the spacer (4).
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214
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Place a mark below the groove on the clutch bell.
Mark the snap ring (11), the discs (18) and the
counterdiscs (17).
These marks will be used as a reference during
assembly.
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216
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
If necessary, remove the seal ring (20) with the
inner O-ring from the outside seat of the piston and
the seal ring (21) with the relevant O-ring from the
inner seat of the piston.
To remove the rings it is necessary to cut them.
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218
SECTION 21 - TRANSMISSION
For the disassembly of other parts, repeat the operations described previously.
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SECTION 21 - TRANSMISSION
Check the seal ring grooves (large and small) for
wear or damage.
Check if the output shaft is worn or damaged.
Check oil passages in the output shaft to be sure
that they are open and free of foreign material.
Check the ball bearings and the needle bearings for
flat areas, pitting or other damage.
If you are to re-use the clutch discs, observe the
assembly order.
Check that the hole of the input shaft on the rear half
box does not show damages that could cause leaks
when the clutch is assembled.
Check that the grooves of the input shaft are not
damaged by the steel discs.
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220
SECTION 21 - TRANSMISSION
A. Reverse
B. Forward
1. Clutch disc (no. 6)
2. Clutch counterdisc (no. 3)
3. Clutch counterdisc (no. 3)
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SECTION 21 - TRANSMISSION
221
A. Reverse
B. Forward
1. Reverse clutch disc (no. 6)
2. Reverse clutch counterdisc (no. 2)
3. Reverse clutch counterdisc (no. 2)
4. Forward clutch disc (no. 7)
5. Forward clutch counterdisc (no. 3)
6. Forward clutch counterdisc (no. 4)
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SECTION 21 - TRANSMISSION
Shaft (D)
Remove the bearing (16) from the shaft (D) by
means of a puller.
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SECTION 21 - TRANSMISSION
Assembly
Shaft (A)
Assemble the seal ring (20) with the relevant O-ring
and the seal ring (21) with the relevant inner O-ring,
respectively in the outer and inner seat of the piston.
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224
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Loosen the knobs of the threaded bars to clear the
spring tension.
Remove the upper part of tool 380200215.
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226
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Assemble the spacer (4).
NOTE: for clarity of the seal ring installation procedure, the following photos do not show the disc kit,
gear, spacer, bearing, and snap ring installed on the
input shaft.
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228
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Assemble tool 380200225 over tool 380200224 and
slide the seal ring until it reaches the groove in the
shaft.
Remove tools 380200224 and 380200225, the
expander/protector and the spacer from the shaft.
Turn the shaft upside down to carry out the operations described previously.
Lubricate the thrust washer (25).
Assemble the thrust washer so that the notch in the
inner edge fits over the pin.
Make sure that the side with the oil grooves is
down.
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230
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Heat the seal ring to 60 80 C (140 176 F) for 5
minutes.
Assemble the seal ring on tool 380001933.
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232
SECTION 21 - TRANSMISSION
In order to insert the other 3 rings, repeat the operations described previously, by means of following
spacer rings:
380001933 for the 2nd ring;
380001933 for the 3rd ring;
380001933 for the 4th ring.
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SECTION 21 - TRANSMISSION
Carry out the check procedure of the clutch disc kit
play on both sides of the clutch.
Position the shaft on a suitable support (S) and
apply load F on the counterdisc (11) surface by
means of a proper buffer (T), as shown.
This operation clears any possible play.
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234
SECTION 21 - TRANSMISSION
Shaft (D)
Assemble the bearing (16) on shaft (D) by means of
tool 380200230.
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SECTION 21 - TRANSMISSION
SHAFT B
Disassembly
Unscrew and remove the screws (28) and remove
the 4WD oil bulkhead (29).
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236
SECTION 21 - TRANSMISSION
WARNING
The seal rings can be damaged.
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SECTION 21 - TRANSMISSION
Remove the bearing (3) and the gear (4) by means
of a puller.
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238
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Push the thrust washer (10) slightly.
239
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240
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Remove the sleeve (18).
241
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242
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
243
Check that the hole of the input shaft on the rear half
box does not show damages that could cause leaks
when the clutch is assembled.
Check that the grooves of the input shaft are not
damaged by the steel discs.
Assembly
Assemble the bearing (25) with tool 380200190.
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244
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Assemble the spring (17) and the cover (16).
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246
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Assemble the snap ring (9).
Supply compressed air at low pressure to the delivery hole to push the thrust washer (10) against the
snap ring (9) and align the disc teeth.
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248
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
249
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250
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
SHAFT C
Disassembly
Unscrew and remove the screws (V1) to detach the
4WD oil bulkhead (P1).
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252
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Remove the bearing (58) by means of a puller.
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254
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Loosen the knobs of the threaded bars to clear the
spring tension.
Remove the upper part of tool 380200215.
Remove the snap ring (41), the cover (42) and the
spring (43).
If necessary, remove the seal ring (45) with the relevant O-ring from the outer seat of piston (44).
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256
SECTION 21 - TRANSMISSION
If necessary, remove the seal ring (53) with the relevant O-ring from the gear seat (54).
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SECTION 21 - TRANSMISSION
Verify the wear condition of the seal rings (49) and
(51).
If necessary, cut the seal rings (49) and (51) to
remove them from bushing (50).
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258
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Remove the pin (22).
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260
SECTION 21 - TRANSMISSION
Remove the snap ring (30), the cover (29) and the
spring (28).
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SECTION 21 - TRANSMISSION
Overturn the shaft (23).
Remove the seal rings (16), (17), (18) and (19) by
cutting them.
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262
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Remove the snap ring (4).
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264
SECTION 21 - TRANSMISSION
Remove the snap ring (9), the cover (10) and the
spring (11).
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SECTION 21 - TRANSMISSION
Remove the bushing (12) and the piston (13).
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266
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
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268
SECTION 21 - TRANSMISSION
Assembly
Assemble the seal ring (53) and the relevant O-ring
on gear (54) by means of tool 380200248.
Assemble the O-ring (52).
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SECTION 21 - TRANSMISSION
Insert the spring (43), the cover (42) and the snap
ring (41).
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270
SECTION 21 - TRANSMISSION
Insert the kit (40) and the thrust washer (39) into the
gear (54).
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SECTION 21 - TRANSMISSION
Insert the piston (26) by means of tool 380001926
to protect the seal rings.
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272
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Assemble the thrust washer (31) by inserting it on
pin (22).
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274
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Insert the gear (54) on the shaft (23).
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276
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Assemble the spacer (57).
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278
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Lower the cover (10) by means of tool 380200215.
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280
SECTION 21 - TRANSMISSION
Supply compressed air at low pressure into the supply hole to push the thrust washer (5) against the
snap ring (4).
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SECTION 21 - TRANSMISSION
Assemble the thrust washer (8) and the roller
retainer (7).
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SECTION 21 - TRANSMISSION
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284
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
The piston stroke (44) must be such to ensure a
play corresponding to:
X = 1.725 2.375 mm (0.068 0.093 in)
If the distance is not within specification, the clutch
is probably wrongly installed.
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286
SECTION 21 - TRANSMISSION
E SHAFT
(Only for 2WS)
Disassembly
Unscrew and remove the screws to detach the 4WD
oil bulkhead.
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SECTION 21 - TRANSMISSION
Assemble on the rear end of the shaft (C) the hub
and tool 380200256.
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288
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Remove the shims (3) and the thrust washer (4).
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290
SECTION 21 - TRANSMISSION
Remove the inner (7) and outer O-ring (9) from the
piston (8).
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SECTION 21 - TRANSMISSION
291
Check that the hole of the input shaft on the rear half
box does not show damages that could cause leaks
when the clutch is assembled.
Check that the grooves of the input shaft are not
damaged by the steel discs.
4WD clutch
Disc number (each side)
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292
SECTION 21 - TRANSMISSION
Assembly
Insert the inner O-ring (7) and the outer O-ring (9)
on the piston (8).
Apply a thin film of grease on the O-rings and position the pins on piston (8) in order to match the
holes of the output shaft.
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SECTION 21 - TRANSMISSION
Overturn the shaft (12) and insert the piston (8).
Insert the counterdisc (14) with the chamfer downwards into the shaft (12).
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294
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Turn the shaft (12).
Make sure that the disc, counterdisc kit and the piston are correctly seated.
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SECTION 21 - TRANSMISSION
0.1
(0.004)
0.3
(0.012)
0.5
(0.02)
Remove the thrust washer (4) and the snap ring (2).
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SECTION 21 - TRANSMISSION
Press the belleville washers and fit the snap ring (2)
by means of tool 380200275.
The springs can cause damages to persons if the
snap ring is not assembled correctly.
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298
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Lift the 3 shafts (B), (C) and (E) at the same time
and insert the assy into the half box by means of
tool 380200239.
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300
SECTION 21 - TRANSMISSION
E SHAFT
(Only for 2WS)
Disassembly
Unscrew and remove the screws to detach the 4WD
oil bulkhead.
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SECTION 21 - TRANSMISSION
Assemble on the rear end of the shaft (C) the hub
and tool 380200256.
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SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Overturn the shaft (13).
Press the belleville washers (5) and remove the
snap ring (2) by means of tool 380200258.
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304
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Remove the counterdisc (16).
Remove the inner (7) and outer O-ring (9) from the
piston (8).
305
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306
SECTION 21 - TRANSMISSION
Check that the hole of the input shaft on the rear half
box does not show damages that could cause leaks
when the clutch is assembled.
Check that the grooves of the input shaft are not
damaged by the steel discs.
4WD clutch
Disc number (each side)
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SECTION 21 - TRANSMISSION
Assembly
Insert the inner O-ring (7) and the outer O-ring (9)
on the piston (8).
Apply a thin film of grease on the O-rings and position the pins on piston (8) in order to match the
holes of the output shaft (12).
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308
SECTION 21 - TRANSMISSION
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Assemble the snap ring (17).
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310
SECTION 21 - TRANSMISSION
0.1
(0.004)
0.3
(0.012)
0.5
(0.02)
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SECTION 21 - TRANSMISSION
Remove the thrust washer (4) and the snap ring (2).
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312
SECTION 21 - TRANSMISSION
Press the belleville washers and fit the snap ring (2)
by means of tool 380200275.
The springs can cause damages to persons if the
snap ring is not assembled correctly.
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SECTION 21 - TRANSMISSION
Assemble the roller retainer (22) and the spacer
(23).
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314
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Lift the 3 shafts (B), (C) and (E) at the same time
and insert the assy into the half box by means of
tool 380200239.
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SECTION 21 - TRANSMISSION
E SHAFT
(Only 4WS)
Disassembly
Unscrew and remove the screws to detach the 4WD
oil bulkhead.
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SECTION 21 - TRANSMISSION
Lift the 3 shafts (B), (C) and (E) simultaneously by
means of tool 380200239.
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318
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Overturn the shaft (17).
Press the belleville washers (5) and remove the
snap ring (2) by means of tool 380200258.
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320
SECTION 21 - TRANSMISSION
Remove the inner (7) and outer O-ring (9) from the
piston (8).
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SECTION 21 - TRANSMISSION
321
Check that the hole of the input shaft on the rear half
box does not show damages that could cause leaks
when the clutch is assembled.
Check that the grooves of the input shaft are not
damaged by the steel discs.
4WD clutch
Disc number (each side)
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SECTION 21 - TRANSMISSION
Assembly
Insert the inner O-ring (7) and the outer O-ring (9)
on the piston (8).
Apply a thin film of grease on the O-rings and position the pins on piston (8) in order to match the
holes of the output shaft (12).
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SECTION 21 - TRANSMISSION
Overturn the bell housing (12) and insert the piston
(8).
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324
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
To value X subtract the fixed measure S1 of
1.80 mm (0.071 in) corresponding to the piston
stroke.
The resulting measure S corresponds to the height
of the shim that must be inserted between the thrust
washer (4) and the snap ring (2).
S = X - S1 = X - 1.80 mm (0.071 in)
0.1
(0.004)
0.3
(0.012)
0.5
(0.02)
Remove the thrust washer (4) and the snap ring (2).
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326
SECTION 21 - TRANSMISSION
Press the belleville washers and fit the snap ring (2)
by means of tool 380200275.
The springs can cause damages to persons if the
snap ring is not assembled correctly.
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SECTION 21 - TRANSMISSION
Turn the shaft (17) and the bell housing (12).
Assemble the bearing (19) with tool 380200229.
Assemble the snap ring (20).
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328
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
Use tool 380200265 to check piston operation and
verify correct adjustment.
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330
SECTION 21 - TRANSMISSION
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SECTION 21 - TRANSMISSION
331
TROUBLESHOOTING
FAULT
The vehicle does not
move.
POSSIBLE CAUSE
ACTION
Damage to sensors.
Replace sensors.
Damaged/restricted filter.
Damaged converter.
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SECTION 21 - TRANSMISSION
FAULT
POSSIBLE CAUSE
The brake does not release.
ACTION
Check the general pressure of
transmission.
Check voltage.
Check the operation of the solenoid
valve.
Check the mounting of the brake
solenoid valve block after operating on
the brake.
After the above-described
verifications, disassemble the brake
cover and check the condition of the
parts for unlocking/locking the brake
(seal rings, belleville washers, brake
disc deformation, etc.).
Overheating.
Damaged converter.
Replace/repair.
Overheated solenoids/solenoid
valves.
Replace.
Replace EGM/ECU.
Damage to sensors.
Replace sensors.
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SECTION 21 - TRANSMISSION
FAULT
Noise.
Irregular coupling.
POSSIBLE CAUSE
333
ACTION
Damaged converter.
Damaged converter.
Ventilation/Cavitation.
Damaged converter.
Overheating.
See overheating.
Replace EGM/ECU.
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SECTION 21 - TRANSMISSION
FAULT
POSSIBLE CAUSE
Replace EGM/ECU.
Replace EGM/ECU.
Replace EGM/ECU.
ACTION
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SECTION 21 - TRANSMISSION
335
REPAIR TIMES
The times are referred to average values of maintenance performed by skilled personnel in workshops
equipped with all necessary fixtures for a proper
execution of the required works.
The repair and/or replacement times are indicated in
minutes.
We assume that the transmission assy has already
been removed from the machine.
ASSY
OPERATION
TIME (minutes)
Converter replacement
10
20
20
40
30
20
80
50
60
Overhauling of shaft A
150
120
60
Overhauling/replacement of shaft B
150
60
Overhauling/replacement of shaft B
180
60
Overhauling/replacement of shaft E
100
60
70
10
40
20
Oil pump
Lines
Control valve
Transmission box
Shafts A and D
Shafts B
Shafts C
Shaft E
Parking brake
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SECTION 21 - TRANSMISSION
SPECIAL TOOLS
PN CNH
DESCRIPTION
USE
380002211
Handle
380200190
Buffer
380200197
Buffer
380200203
Buffer
380200214
Calibrator
380200215
Attachment
380200218
Buffer
380200223
Check
Piston check
380200224
380200225
Plunger
380001926
Protection
380200226
Buffer
380200230
Buffer
380200240
380001933
380001927
Calibrator
380001928
Plunger
380200241
Calibrator
380200239
Hook
380200257
Protection
380200242
Plunger
380200248
Protection
380200250
Calibrator
380200251
380200252
Plunger
380200253
Calibrator
380200256
Sleeve
Shaft disassembly
380200275
Tool
380200258
Puller
380200220
Drift
380200229
Drift
2WS 4WS
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580T
580ST
590ST
695ST
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2
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SECTION 25 - FRONT AXLE
Manufacturer
Model
CNH
Steering
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4
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SECTION 25 - FRONT AXLE
Before draining the oil from the axle body, use the
breather (2) to release any possible internal pressure.
WARNING
Risk of violent oil ejection.
WARNING
Risk of violent oil ejection.
Drain all oil.
Clean, screw in and tighten the drain plug (4).
Fill through the hole of the plug (1).
Check the level and, if necessary, top up.
Clean, screw and tighten the plug (1).
Before draining the oil from the reduction gear,
rotate it so that the plug (3) is in the highest position
(position A) and partially unscrew the plug to
release any possible internal pressure.
Turn and bring the plug to the lowest position (position B).
Remove the plug and drain the oil.
Now turn again and bring the hole of the plug (3) to
check and oil filling position (position C).
Carry out the filling.
Clean, screw and tighten the plug (3).
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SECTION 25 - FRONT AXLE
TROUBLESHOOTING
FAULT
Bent axle beam body.
POSSIBLE CAUSE
ACTION
Overloaded vehicle.
Damaged vehicle.
Insufficient lubrication.
Contaminated oil.
Excessive use.
Normal wear.
Contaminated oil.
Incorrect installation.
Faulty differential.
Overload.
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8
FAULT
Difficult steering; the machine
travels in a straight line while
steering.
Excessive noise.
Friction noise.
POSSIBLE CAUSE
ACTION
Incorrect installation.
Faulty differential.
Overload.
Incorrect installation.
Faulty differential.
Overload.
Incorrect installation.
Faulty differential.
Overload.
Incorrect installation.
Discard.
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SECTION 25 - FRONT AXLE
FAULT
Vibrations during travel.
Intermittent noise.
POSSIBLE CAUSE
ACTION
Incorrect installation.
Faulty differential.
Overload.
Incorrect installation.
Faulty differential.
Overload.
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10
Manufacturer
Model
CNH
Steering
Steering angle
Lubrication angle
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SECTION 25 - FRONT AXLE
11
Oil capacity
Oil type
Differential
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12
Before draining the oil from the axle body, use the
breather (2) to release any possible internal pressure.
WARNING
Risk of violent oil ejection.
WARNING
Risk of violent oil ejection.
Drain all oil.
Clean, screw in and tighten the drain plug (4).
Fill through the hole of the plug (1).
Check the level and, if necessary, top up.
Clean, screw and tighten the plug (1).
Before draining the oil from the reduction gear,
rotate it so that the plug (3) is in the highest position
(position A) and partially unscrew the plug to
release any possible internal pressure.
Turn and bring the plug to the lowest position (position B).
Remove the plug and drain the oil.
Now turn again and bring the hole of the plug (3) to
check and oil filling position (position C).
Carry out the filling.
Clean, screw and tighten the plug (3).
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SECTION 25 - FRONT AXLE
REMOVAL FROM MACHINE
Move the machine to a level and firm ground, away
from any soft ground, excavations and poorly
shored cavity.
Rest the loader attachment on the ground in order to
unload the weight of the machine from the 2 front
wheels, then lift the front part, thus ensuring the
safety of the subsequent operations.
Use the locking pin (if provided) to lock the loader
attachment controls.
Place the backhoe attachment in the road travel
position.
Place the direction-of-travel lever and gearshift lever
in neutral position.
Immobilize the machine by means of the parking
brake.
Completely raise the stabilizers and lock them
mechanically.
Stop the engine and remove the starter key.
Release the hydraulic pressure by operating the
control levers in all directions.
On hydraulically controlled machines, turn the key to
ON and release the pressure by moving the hydraulic control levers in all directions.
Place some wedges under the wheels so as to prevent the machine from moving.
Disconnect the electric system by disconnecting the
battery master switch.
Fasten the front axle (4) to a lifting hoist or to a support.
Now it is possible to carry out the disassembly of
the 2 front tyres by loosening and removing the relevant fixing nuts (5) [tightening torque = 330 Nm
(243 lbfft)].
Disconnect the hoses of the steering cylinder, paying attention to possible oil leaks, preventing spillage over the ground using a container.
Disconnect the cardan joint (1).
Loosen and remove the screws (2) with the relevant washers (3) [tightening torque = 460 540 Nm
(339 398 lbfft)].
Remove the front axle (4).
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14
Breather
11 14 Nm (8 10 lbfft)
54 66 Nm (40 49 lbfft)
20 30 Nm (15 22 lbfft)
21 26 Nm (15.5 19 lbfft)
154 188 Nm (114 139 lbfft)
72 88 Nm (53 65 lbfft)
21 26 Nm (15.5 19 lbfft)
Pinion
Differential
8 25 Nm (6 18 lbfft)
12 25 Nm (9 18 lbfft)
Standard differential
0 1 Nm (0 0.7 lbfft)
1 5 Nm (0.7 4 lbfft)
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SECTION 25 - FRONT AXLE
WHEEL HUB
Disassembly
Unscrew and remove the plug (1) and drain the oil.
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16
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SECTION 25 - FRONT AXLE
Mark the washers and grease the pins.
17
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18
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SECTION 25 - FRONT AXLE
Loosen and remove the screws (10).
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20
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SECTION 25 - FRONT AXLE
Remove the snap ring (12) which fastens the ring
gear (6) in the ring gear carrier (11).
Separate the ring gear carrier (11) and the ring gear
(6).
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22
Checks
Clean all parts in cleaning solvent.
Inspect the bearing cup and the rollers in the bearings for flat areas, pitting, scoring, and other damage. Also check the inner race for damage. If any of
these defects are found, new bearings and new
bearing cups must be installed.
Inspect the pins for wear and damage.
Inspect the teeth of the gears and of the ring gear
for wear, pitting, scoring or other damage.
Use new parts as required.
Assembly
If bearing cups were removed, use an acceptable
driver to press new bearing cups into the wheel
hub.
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SECTION 25 - FRONT AXLE
Insert the new rollers using tool DMT100002.
23
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24
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SECTION 25 - FRONT AXLE
Press the bushings (14) into the ring gear carrier
(11).
25
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26
Align the holes in the ring gear carrier (11) with the
holes in the swivel housing and install the ring gear
carrier.
Tighten the ring nut (5) using tool 380000468, to a tightening torque of 358 442 Nm (264 326 lbfft).
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SECTION 25 - FRONT AXLE
Assemble a new O-ring (4).
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28
SWIVEL HOUSING
Disassembly
Unscrew and remove the tie rod nut (1).
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SECTION 25 - FRONT AXLE
Use a two-jaw puller to loosen the ball joint.
29
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30
Remove the screws (6) and the top king pin (7).
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SECTION 25 - FRONT AXLE
Remove the bearing (8) from the top and bottom of
the axle body by means of a puller.
Remove the bearing cup (8) from the king pin (7)
using a hammer and a chisel.
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Assembly
Install the bushing
DMT100005.
(16)
by
means
of
tool
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SECTION 25 - FRONT AXLE
Assemble the top king pin (7).
Tighten the screws (6) to a tightening torque of
154 188 Nm (114 139 lbfft).
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34
CARDAN JOINT
Disassembly
Remove the 4 snap rings (3).
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SECTION 25 - FRONT AXLE
Use the CAS1980 V-block to support the coupling (5).
Adjust the screws in the V-block to hold the coupling
level.
Use a driver and press the bottom bearing cup
against the V-block.
Fasten the bearing cup in a vice and drive the coupling off the bearing cup.
Remove the long axle shaft (2) from the coupling (5).
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SECTION 25 - FRONT AXLE
Remove the cross (4).
Press the bearing cup into the yoke until the top of
the bearing cup is 6 mm (0.24 in) above the top of
the yoke.
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38
Press the other bearing cup into the yoke until the
top of the bearing cup is 9 mm (0.35 in) above the
top of the yoke.
Hold the cross and press the bearing cups into the
yoke.
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SECTION 25 - FRONT AXLE
Assemble the snap ring (3).
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40
Hold the cross and press the bearing cup into the
coupling so that a snap ring can be installed.
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SECTION 25 - FRONT AXLE
DIFFERENTIAL
Disassembly
Loosen and remove the differential carrier screws
(1).
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SECTION 25 - FRONT AXLE
Loosen and remove the screws (29) and the washers (28).
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SECTION 25 - FRONT AXLE
Remove the washers (8) and (10) and the spacer
(9).
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SECTION 25 - FRONT AXLE
Remove the gear (18).
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48
Checks
Clean all parts in cleaning solvent.
Inspect the bearing cups and the bearings for flat
areas, pitting, scoring and other damage.
Also check the inner race for damage. If any of
these defects are found, new bearings and bearing
cups must be installed.
Inspect the teeth on the pinion and of the ring gear
for pitting, scoring and broken teeth. The ring gear
and pinion gear must be replaced as a set.
Inspect the gears, the pins and the teeth of the pinion gears for pitting, scoring and other damage.
Also inspect the thrust surfaces and the bores of
each gear. Check the splines in the gears for wear.
Inspect the thrust washers for pitting, scoring and
other damage.
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SECTION 25 - FRONT AXLE
Assembly
Assemble the thrust washer (24) and the gear (23).
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50
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SECTION 25 - FRONT AXLE
Press the bearing (11) against the shim.
Use a feeler gauge to ensure bearing is fully
seated.
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SECTION 25 - FRONT AXLE
When the rotating torque is as specified, use a
hammer and punch and partially drive the nut (5)
into the slot in the pinion.
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SECTION 25 - FRONT AXLE
Make the final adjustments of the ring nuts to align
locking devices and confirm the rolling torque.
Apply the yellow compound on the bevel set in 3
places, 120 apart, on 3 teeth each.
Rotate bevel set enough to see pattern in yellow
compound.
Pattern should be per chart above.
Normal wear will flatten (elongate) the contact pattern.
NOTE: this is a non-adjustable bevel set. If pattern
is significantly different from specifications, then
replace bevel set.
If the original ring gear and pinion gear are being
used, the backlash must be equal to the measurement made during disassembly.
Tighten the screws (26) to the prescribed torque
of 266 Nm (196 lbfft).
Screw in the lock screw (29) which blocks the
ring gear and tighten to a tightening torque of
162 200 Nm (119 147 lbfft).
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SECTION 25 - FRONT AXLE
57
TROUBLESHOOTING
FAULT
Ring gear tooth broken on the
outer side.
POSSIBLE CAUSE
Excessive gear load compared to
the one expected.
Load bump.
ACTION
Inappropriate lubricant.
Excessive use.
Insufficient lubrication.
Overloaded vehicle.
Damaged vehicle.
Insufficient lubrication.
Contaminated oil.
Excessive use.
Normal wear.
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58
FAULT
Oil leakage form the seals.
POSSIBLE CAUSE
ACTION
Contaminated oil.
Excessive use.
Excessive use.
Inappropriate lubricant.
Contaminated oil.
Excessive use.
Replace bearing.
Insufficient lubrication
Contaminated oil.
Continuous overload.
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SECTION 25 - FRONT AXLE
FAULT
POSSIBLE CAUSE
59
ACTION
Incorrect installation.
Faulty differential.
Overload.
Incorrect installation.
Faulty differential.
Overload.
Incorrect installation.
Faulty differential.
Overload.
Excessive noise.
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60
FAULT
Uneven wear of tyre.
Friction noise.
Intermittent noise.
POSSIBLE CAUSE
ACTION
Incorrect installation.
Faulty differential.
Overload.
Incorrect installation.
Discard.
Incorrect installation.
Faulty differential.
Overload.
Incorrect installation.
Faulty differential.
Overload.
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SECTION 25 - FRONT AXLE
61
SPECIAL TOOLS
PN CNH
DESCRIPTION
USE
CAS-1980
V-block
380100103
Protection
DMT100001
Protection
DMT100002
Tool
Assembly of bearings
DMT100004
Buffer
DMT100005
Buffer
DMT100006
Buffer
DMT100007
Tool
380000468
Wrench
380100102
Wrench
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62
Manufacturer
CARRARO
Model
26.32
Differential ratio
2.75
6.92
19.04
Lubrication angle
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SECTION 25 - FRONT AXLE
63
Oil capacity
Oil type
Differential
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64
Before draining the oil from the axle body, use the
breather (2) to release any possible internal pressure.
WARNING
Risk of violent oil ejection.
WARNING
Risk of violent oil ejection.
Drain all oil.
Clean, screw in and tighten the drain plug (4).
Fill through the hole of the plug (1).
Check the level and, if necessary, top up.
Clean, screw and tighten the plug (1).
Before draining the oil from the reduction gear,
rotate it so that the plug (3) is in the highest position
(position A) and partially unscrew the plug to
release any possible internal pressure.
Turn and bring the plug to the lowest position (position B).
Remove the plug and drain the oil.
Now turn again and bring the hole of the plug (3) to
check and oil filling position (position C).
Carry out the filling.
Clean, screw and tighten the plug (3).
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SECTION 25 - FRONT AXLE
REMOVAL FROM MACHINE
Move the machine to a level and firm ground, away
from any soft ground, excavations and poorly
shored cavity.
Rest the loader attachment on the ground in order to
unload the weight of the machine from the 2 front
wheels, then lift the front part, thus ensuring the
safety of the subsequent operations.
Use the locking pin (if provided) to lock the loader
attachment controls.
Place the backhoe attachment in the road travel
position.
Place the direction-of-travel lever and gearshift lever
in neutral position.
Immobilize the machine by means of the parking
brake.
Completely raise the stabilizers and lock them
mechanically.
Stop the engine and remove the starter key.
Release the hydraulic pressure by operating the
control levers in all directions.
On hydraulically controlled machines, turn the key to
ON and release the pressure by moving the hydraulic control levers in all directions.
Place some wedges under the wheels so as to prevent the machine from moving.
Disconnect the electric system by disconnecting the
battery master switch.
Fasten the front axle (6) to a lifting hoist or to a support.
Now it is possible to carry out the disassembly of the 2
front tyres by loosening and removing the relevant fixing nuts (7) [tightening torque = 700 Nm (516 lbfft)].
Disconnect the hoses of the steering cylinder, paying attention to possible oil leaks, preventing spillage over the ground using a container.
Disconnect the cardan joint (1) by unlocking and
removing the screws (2) and the bracket (3).
Loosen and remove the screws (5) with the relevant
washers (4).
Remove the front axle (6).
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66
NOTES:
Copyright
580T
580ST
590ST
695ST
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2
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SECTION 27 - REAR AXLE
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4
Manufacturer
CARRARO
Model
28.44
2.75/1
6.40/1
17.6/1
Input rotation
Dry weight
Differential type
Pressure for differential lock
Bevel gear set backlash
clockwise
420 kg
(926 lb)
Mechanical and driven
12 35 bar
(174 508 psi)
0.20 0.28 mm
(0.0079 0.0110 in)
FP = 115 138 N
(26 31 lbf)
MP = 2.0 2.4 Nm
(1.47 1.77 lbfft)
MT = (MP + 0.58) (MP + 0.87) Nm
[MT = (MP + 0.43) (MP + 0.64) lbfft]
SERVICE BRAKE
Brake type
16 cm 3 (0.98 in3)
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SECTION 27 - REAR AXLE
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6
Before draining the oil from the axle body, use the
breather (3) to release any possible internal pressure.
WARNING
Risk of violent oil ejection.
WARNING
Risk of violent oil ejection.
Drain all oil.
Clean the plug (2), screw it and tighten to the prescribed torque of 80 Nm (59 lbfft).
Fill through the hole of the plug (1).
Check the level and, if necessary, top up.
Clean the plug (2), screw it and tighten to the prescribed torque of 80 Nm (59 lbfft).
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SECTION 27 - REAR AXLE
REMOVAL FROM MACHINE
Move the machine to a level and firm ground, away
from any soft ground, excavations and poorly
shored cavity.
Lower the loader attachment to the ground.
Use the locking pin (if provided) to lock the loader
attachment controls.
Lower the backhoe attachment to the ground.
Place the direction-of-travel lever and gearshift lever
in neutral position.
Immobilize the machine by means of the parking
brake.
Lower the stabilizers until the rear wheels are
slightly lifted from the ground (they are free from
machine weight).
Stop the engine and remove the starter key.
Release the hydraulic pressure by operating the
control levers in all directions.
On hydraulically controlled machines, turn the key to
ON and release the pressure by moving the hydraulic control levers in all directions.
Disconnect the electric system by disconnecting the
battery master switch.
Fasten the rear axle to a lifting hoist or to a support.
Now it is possible to carry out the disassembly of the
2 rear tyres by loosening and removing the relevant
fixing nuts (9) [tightening torque = 700 Nm (516 lbfft)].
Disconnect the cardan joint (6) by unlocking and
removing the screws (7) and the bracket (8).
Unscrew and remove the screws (4) with the nuts
(2) and the washers (3) and (5) [tightening torque
= 610 678 Nm (445 500 lbfft)].
Remove the rear axle (1).
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SECTION 27 - REAR AXLE
GREASE POINTS
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10
FRONT FLANGE
Disassembly
Remove the stop ring (1) and the front flange (2).
Remove the O-ring (4) and the shim (5).
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SECTION 27 - REAR AXLE
Assembly
Assemble the seal ring (3) into the central body with
a drift 380200228 and a hammer.
Insert the shim (5) and a new O-ring (4) into the pinion shaft.
Insert the front flange (2) on the shaft end.
Fasten the pieces as soon as assembled by fitting
the snap ring (1).
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12
BRAKES
Disassembly
Drain the oil completely from the differential.
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SECTION 27 - REAR AXLE
Connect the wheel hub (2) to a lifting device and
tension the rope.
Insert 2 opposed threaded rods to enable removal.
Slowly remove the wheel hub assy and the half axle
(4), make sure that the braking discs (5) and the
counterdiscs (6) stay on the wheel hub assy.
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14
Remove the half axle (4) from the wheel hub assy
(2).
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SECTION 27 - REAR AXLE
Remove the snap ring (11) and the self adjust kit
assy (12).
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16
Remove the brake piston (15) from the brake cylinder (10).
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SECTION 27 - REAR AXLE
Assembly
Assemble the O-ring (19).
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SECTION 27 - REAR AXLE
Assemble the snap rings (13) until they are seated
against the calibrated disc and using a drift
380200245.
Repeat the procedure for the remaining 2 self
adjust kits.
Assemble the self adjust kits (12) into the brake cylinder, paying attention to direct the chamfer edge of
the bushing (14) upwards.
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20
Using the reference mark made during disassembly, assemble the counterdisc (5) paying attention to
direct it with the mark towards the axle body (3).
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SECTION 27 - REAR AXLE
Assemble the first braking disc (6) and the counterdisc (5).
If using new brake discs (6), they must be soaked in
oil for at least 24 hours prior to installation.
Assemble the last brake disc (6) and make sure that
its slots are aligned with those of the first disc.
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WHEEL HUB
Disassembly
Remove the brake assy.
If disassembly of the planetary gear carrier for overhauling is not necessary, use a bearing puller to lift
the planetary gear carrier assy.
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SECTION 27 - REAR AXLE
Enlarge the snap ring (2) and simultaneously
extract the gear carrier (1).
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24
Remove the bearing cup (9) from the wheel hub (7).
Remove the seal ring (10) from the wheel hub (7).
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SECTION 27 - REAR AXLE
Remove the spacer (12) from the wheel flange (8).
Assembly
Assemble the bearing cup (11) onto wheel hub (7)
with the buffer 380200211.
Assemble the bearing cup (9) with the buffer
380002222.
Assemble the seal ring (10) on the wheel hub (7)
with the buffer 380200254.
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SECTION 27 - REAR AXLE
Screw in and tighten the ring nut (6) with tool
380200244 at tightening torque of 1000 Nm (738
lbfft).
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28
Enlarge the snap ring (2) to complete the gear carrier (1) assembly.
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SECTION 27 - REAR AXLE
DIFFERENTIAL SUPPORT ASSY
Disassembly
Drain the oil completely from the differential.
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30
Separate the axle support (3) from the axle body (2)
using pry bars in slots.
Measure the rolling torque MT0 of the bearings (pinion-ring gear system), using wrench 380200269.
Note value MT0 that is necessary for assembling the
bearings.
NOTE: the total rolling torque must be determined
without the pinion seal ring.
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SECTION 27 - REAR AXLE
Unscrew and remove the screws (4) fastening the
ring nuts (5) and (6).
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Assembly
Assemble the bearing cups (8) and (9) on the differential box (7) with drift 380200218.
Tighten both ring nuts (5) and (6) with special tool
380200243, till the backlash is eliminated and the
bearings are slightly preloaded.
Check that the bearings are correctly seated.
Position a magnetic-base dial gauge on the differential support, so that the feeler touches the surface
of one tooth of the ring gear with a 90 angle.
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SECTION 27 - REAR AXLE
Lock the pinion and alternately move the ring gear,
and note the backlash between pinion and ring
gear, measured with the dial gauge.
Repeat the operation on two or more points (teeth),
rotating the ring gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.20 0.28 mm (0.0079 0.0110 in)
Carry out the adjustment by operating on the ring
nuts (5) and (6) with tool 380200243.
Adjust the ring nuts (5) and (6), remembering that:
- if the measured backlash is less than the prescribed tolerance range, unscrew the ring nut (6)
and screw in the ring nut (5) by the same measure;
- if the measured backlash is more than the prescribed tolerance range, unscrew the ring nut (5)
and screw in the ring nut (6) by the same measure.
Repeat the whole sequence of the above mentioned operations until the requested conditions are
reached.
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SECTION 27 - REAR AXLE
Once the pinion-ring gear backlash has been
adjusted, if the bearings have been replaced, measure the total rolling torque MTm of the bearings (pinion-ring gear system) with a torque meter and the
wrench 380200269.
WARNING
All preloads must be measured without seal rings.
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SECTION 27 - REAR AXLE
Check of the bevel gear
To test the marks of the bevel gear teeth, paint the
ring gear with red lead paint.
The contact mark test should always be carried out
on the ring gear teeth and on both sides.
Movements to correct:
1 -> move the pinion for type X contact adjustment;
2 -> move the pinion for type Z contact adjustment.
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DIFFERENTIAL LOCKING ASSY
Disassembly
Loosen plug (1) without removing it.
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SECTION 27 - REAR AXLE
Push the yoke (2) downwards using the differential
support as a retainer, then remove the plug (1).
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40
Remove the yoke (2), the spring (7) and the spacer
(8) from the rod (3).
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SECTION 27 - REAR AXLE
Assembly
Assemble the O-rings (11) and (12) onto the piston
(10).
Assemble the O-ring (9) on the plug (1).
Lubricate the O-rings.
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SECTION 27 - REAR AXLE
Tighten the plug (1) to the requested torque of 80 Nm
(59 lbfft).
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44
DIFFERENTIAL
Disassembly
If differential bearings must be replaced, remove
the bearing cups (1) and (2).
Remove the sleeve (3).
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SECTION 27 - REAR AXLE
Remove the snap ring (4).
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SECTION 27 - REAR AXLE
Remove the pin (13), the planetary gear (16) and
the relevant shoulder ring (17).
Remove the pins (18), the gears (20) and the relevant shoulder rings (21).
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48
Assembly
Assemble the O-rings (26) on the pins (25).
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SECTION 27 - REAR AXLE
Assemble the gears (20) and the relevant shoulder
rings (21). Insert pins (18) far enough to hold them.
NOTE: orient the pins with the flat side upwards.
Lubricate and assemble the gear (16) and the relevant shoulder ring (17).
Insert pin (13).
Orient the pin (13) with the flat side upwards.
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Insert the pins (10) and tighten the plugs (9) to the
prescribed torque.
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SECTION 27 - REAR AXLE
Assemble the anti-rotation pin (6) on the cover (5).
Assemble the cover (5) onto the differential box.
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PINION ASSY
Disassembly
Measure the starting preload FP0 of the pinion bearings using a dynamometer whose cord is wound on
the end of the pinion shaft.
WARNING
Note value FP0 that is necessary for assembling the
bearings.
WARNING
Note value MP0 that is necessary for assembling
the bearings.
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SECTION 27 - REAR AXLE
Lock the differential assy in a vice.
Unscrew the ring nut (1) using special tools
380000021 and 380000020.
NOTE: this operation will irretrievably damage the
lock nut (1).
Remove the ring nut (1) and collect its washer (2).
Remove the bearing cups (7) and (8) from the differential support (9) using a buffer and a hammer.
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SECTION 27 - REAR AXLE
Assembly
Place the differential support (9) on a workbench.
Insert the bearing cups (7) and (8) with the buffers
380200200 and 380002215 and a hammer.
Use a depth gauge to measure dimension X (distance between bearing axis of differential box and
leaning point of pinion head or bearing base).
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Select the shim (10) with value (S) from the range
of available shims, and fit it onto the shaft end under
the pinion head.
SHIM RANGE
Shims
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
mm
(0.098) (0.102) (0.106) (0.110) (0.114) (0.118) (0.122) (0.126) (0.130) (0.134)
(in)
Q.ty
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SECTION 27 - REAR AXLE
Once you have chosen the suitable shim (10), insert
it on the pinion shaft with the chamfer against the
pinion head.
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58
Insert the washer (2) and tighten the new ring nut
(1) on the pinion shaft.
Lubricate the ring nut thread (1) and the supporting
face with the washer (2) with oil.
Screw in the ring nut (1) using the wrench for ring
nut 380200268 and the pinion retainer 380200269.
WARNING
The tightening torque is given by the measure of
the preload on bearings (7) and (8); gradually
tighten the ring nut (1).
NOTE: if the tightening is excessive, the spacer (6)
must be replaced and the procedure repeated.
When you check the preload, strike the pinion end
(3) with a soft hammer to favour the bearings (7)
and (8) settlement.
If the bearings have not been replaced, to measure
the preload FPm of the bearings (7) and (8), use a
dynamometer whose cord is wound on the end of
pinion shaft (3).
WARNING
Use this method only if the bearings are not to be
replaced, otherwise go to next step.
The measured value should be within the following
range:
FPm = FP0 (FP0 + 10) N
[FPm = FP0 (FP0 + 2.25) lbf]
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SECTION 27 - REAR AXLE
If the bearings have not been replaced, it is possible
to measure the rolling torque MPm of the bearings
(7) and (8), using a torque wrench and tool
380000020.
NOTE: use this method only if the bearings are not
replaced.
WARNING
All preloads must be measured without seal rings.
The measured value should be the same of the
starting:
MPm = MP0
If the bearings (7) and (8) are new, to measure the
preload FPm of the bearings, use a dynamometer
whose cord is wound on tool 380200237, inserted
on the end of pinion shaft.
WARNING
Values for new bearings.
In case you do not use the prescribed tool to measure the preload, the reference diameter is the diameter of pinion shaft splined end.
The measured value should be within the following
range:
FPm = 115 138 N
[FPm = 25.85 31.02 lbf]
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WARNING
All preloads must be measured without seal rings.
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SECTION 27 - REAR AXLE
61
TROUBLESHOOTING
FAULT
Wheel vibrations.
Tyre resistance.
POSSIBLE CAUSE
ACTION
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
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62
FAULT
Excessive noise.
Friction noise.
POSSIBLE CAUSE
ACTION
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
Axle faulty.
Overload.
Differential locked.
Incorrect installation.
Incorrect installation.
Axle faulty.
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SECTION 27 - REAR AXLE
FAULT
Outer tip of ring gear tooth is
broken.
POSSIBLE CAUSE
Excessive gear load compared to
the one expected.
Crash load.
Insufficient lubrication.
Contaminated lubricant.
ACTION
63
Contaminated lubricant.
Drive pinion teeth pitted.
Insufficient lubrication.
Machine overloaded.
Damaged vehicle.
Crash load.
Bearings worn or pitted.
Insufficient lubrication.
Contaminated lubricant.
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64
FAULT
Gaskets leak oil.
POSSIBLE CAUSE
ACTION
Intense use.
Intense use.
Intense use.
Insufficient lubrication.
Continuous overload.
Lubrication wrong.
Contaminated lubricant.
Intense use.
Replace bearing.
Unsuitable lubrication.
Contaminated lubricant.
Broken or bent axle beam.
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SECTION 27 - REAR AXLE
FAULT
Noise during travel.
Intermittent noise.
Constant noise.
POSSIBLE CAUSE
65
ACTION
Change lubricant.
Worn bearings.
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66
FAULT
Noise while bending.
POSSIBLE CAUSE
ACTION
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SECTION 27 - REAR AXLE
67
REPAIR TIMES
The times are referred to average values of maintenance performed by skilled personnel in workshops
equipped with all necessary fixtures for a proper
execution of the required works.
The repair and/or replacement times are indicated in
minutes.
We assume that the axle has already been removed
from the machine.
ASSY
Connection flange
OPERATION
TIME (minutes)
30
240
240
210
O-ring replacement (x 1)
30
50
40
90
105
60
30
180
150
Differential
240
Differential locking
30
Pinion
180
Wheel hub
Brake
Differential support
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68
SPECIAL TOOLS
PN CNH
DESCRIPTION
USE
380002211
Handle
380000021
Wrench
380200187
380002215
Buffer
380000020
Wrench
380002222
Buffer
380200200
Buffer
380200202
False pinion
380200204
Buffer
380200211
Buffer
380200218
Buffer
380200228
Drift
380200237
Tool
380200243
Wrench
380200244
Wrench
380200245
Buffer
380200254
Buffer
380200255
Buffer
380200259
Plunger
380200260
Guide
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SECTION 27 - REAR AXLE
69
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70
Manufacturer
CARRARO
Model
28.50
2.75/1
6.40/1
17.6/1
Input rotation
clockwise
Dry weight
472 kg
(1040 lb)
Differential type
Pressure for differential lock
Bevel gear set backlash
SERVICE BRAKE
Brake type
16 cm 3 (0.98 in3)
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SECTION 27 - REAR AXLE
71
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72
Before draining the oil from the axle body, use the
breather (3) to release any possible internal pressure.
WARNING
Risk of violent oil ejection.
WARNING
Risk of violent oil ejection.
Drain all oil.
Clean the plug (2), screw it and tighten to the prescribed torque of 80 Nm (59 lbfft).
Fill through the hole of the plug (1).
Check the level and, if necessary, top up.
Clean the plug (2), screw it and tighten to the prescribed torque of 80 Nm (59 lbfft).
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SECTION 27 - REAR AXLE
REMOVAL FROM MACHINE
Move the machine to a level and firm ground, away
from any soft ground, excavations and poorly
shored cavity.
Lower the loader attachment to the ground.
Use the locking pin (if provided) to lock the loader
attachment controls.
Lower the backhoe attachment to the ground.
Place the direction-of-travel lever and gearshift lever
in neutral position.
Immobilize the machine by means of the parking
brake.
Lower the stabilizers until the rear wheels are
slightly lifted from the ground (they are free from
machine weight).
Stop the engine and remove the starter key.
Release the hydraulic pressure by operating the
control levers in all directions.
On hydraulically controlled machines, turn the key to
ON and release the pressure by moving the hydraulic control levers in all directions.
Disconnect the electric system by disconnecting the
battery master switch.
Fasten the rear axle to a lifting hoist or to a support.
Now it is possible to carry out the disassembly of
the 2 rear tyres by loosening and removing the
relevant fixing nuts (9) [tightening torque = 700 Nm
(516 lbfft)].
Disconnect the cardan joint (6) by unlocking and
removing the screws (7) and the bracket (8).
Unscrew and remove the screws (4) with the nuts
(2) and the washers (3) and (5) [tightening torque =
610 678 Nm (445 500 lbfft)].
Remove the rear axle (1).
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SECTION 27 - REAR AXLE
GREASE POINTS
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FRONT FLANGE
Disassembly
Remove the stop ring (1) and the front flange (2).
Collect shim (4) and the O-ring (3).
Take out the seal ring (5) from the central body (6).
WARNING
The seal ring can be damaged.
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SECTION 27 - REAR AXLE
If necessary, remove protection (7) from the front
flange (2).
Assembly
On the front flange (2), assemble the protection (7)
using tool 380200277.
Insert a new seal ring (5) into the central body (6)
using tool 380200276.
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Use tool 380200276 to fit the seal ring (5) into the
central body (6).
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SECTION 27 - REAR AXLE
BRAKES
Disassembly
Drain the oil completely from the differential.
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Slowly remove the wheel hub assy and the half axle
(4), make sure that the discs (5) and the counterdiscs (6) stay on the wheel hub assy.
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SECTION 27 - REAR AXLE
Remove the half axle (4) from the wheel hub assy
(2).
Remove the snap ring (11) and the self adjust kit
assy (12).
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Remove the brake piston (15) from the brake cylinder (10).
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SECTION 27 - REAR AXLE
Remove the O-rings (16) and (17) from the brake
cylinder (10).
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Assembly
Assemble the new O-ring (19).
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SECTION 27 - REAR AXLE
Lubricate the seat of the brake cylinder on the
wheel hub (2) and assemble the dowel pins (7).
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Assemble the self adjust kits (12) into the brake cylinder, paying attention to direct the chamfer edge of
the bushing (14) upwards.
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SECTION 27 - REAR AXLE
Assemble the belleville washers (9) on the screws
(8) paying attention to orient them correctly.
Using the reference mark made during disassembly, assemble the counterdisc (5) paying attention to
direct it with the mark towards the axle body (3).
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Assemble the first braking disc (6) and the counterdisc (5).
If using new brake discs (6), they must be soaked in
oil for at least 24 hours prior to installation.
Assemble the last brake disc (6) and make sure that
its slots are aligned with those of the first disc.
Screw in screws (1) applying the prescribed sealant and tighten to tightening torque of 226 Nm
(167 lbfft).
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SECTION 27 - REAR AXLE
WHEEL HUB
Disassembly
Remove the brake assy.
If disassembly of the planetary gear carrier for overhauling is not necessary, use a bearing puller to lift
the planetary gear carrier assy.
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Separate the hub (7) from the wheel flange (8) with
a puller.
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SECTION 27 - REAR AXLE
Connect the hub (7) to a hoisting tool to remove it.
Collect the bearing (9).
Remove the bearing cup (9) from the wheel hub (7).
Remove the seal ring (10) from the wheel hub (7).
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Assembly
Assemble the bearing cup (11) onto wheel hub (7)
with the buffer 380200211.
Assemble the bearing cup (9) with the buffer
380002222.
Assemble the seal ring (10) on the wheel hub (7)
with the buffer 380200254.
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SECTION 27 - REAR AXLE
Assemble the bearing (11) onto wheel flange (8)
with a press.
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SECTION 27 - REAR AXLE
Orient the gear carrier so that the tooth engages
into the ring nut (6).
Enlarge the snap ring (2) to complete the gear carrier (1) assembly.
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Disassembly
Drain the oil completely from the differential.
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SECTION 27 - REAR AXLE
Separate the axle support (3) from the axle body (2)
using pry bars in slots.
Measure the rolling torque MT0 of the bearings (pinion-ring gear system), using wrench 380200269.
Note value MT0 that is necessary for assembling the
bearings.
NOTE: the total rolling torque must be determined
without the pinion seal ring.
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SECTION 27 - REAR AXLE
Assembly
Assemble the bearing cups (8) and (9) on the differential box (7) with drift 380200218.
Tighten both ring nuts (5) and (6) with special tool
380200243, till the backlash is eliminated and the
bearings are slightly preloaded.
Check that the bearings are correctly seated.
Position a magnetic-base dial gauge on the differential support, so that the feeler touches the surface
of one tooth of the ring gear with a 90 angle.
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Repeat the whole sequence of the above mentioned operations until the requested conditions are
reached.
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SECTION 27 - REAR AXLE
Once the pinion-ring gear backlash has been
adjusted, if the bearings have not been replaced,
measure the total rolling torque MTm of the bearings
(pinion-ring gear system) with a torque meter and
the special wrench 380200269.
The measured value MTm should be the same of
the starting:
MTm = MT0
WARNING
All preloads must be measured without seal rings.
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Movements to correct:
1 -> move the pinion for type X contact adjustment;
2 -> move the pinion for type Z contact adjustment.
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SECTION 27 - REAR AXLE
Once all the adjustment operations have been completed, fit the ring nuts (5) and (6) by tightening the
screws (4).
Tighten the screws (4) to a tightening torque of 10 Nm
(7.4 lbfft).
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DIFFERENTIAL LOCKING ASSY
Disassembly
Loosen plug (1) without removing it.
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SECTION 27 - REAR AXLE
Push the yoke (2) downwards using the differential
support as a retainer.
Remove the plug (1).
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Remove the springs (4) and (8) and the spacer (9).
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SECTION 27 - REAR AXLE
Remove the O-ring (14) from the plug (7).
Assembly
Assemble the O-ring (14) on the plug (7).
Assemble the rod (3) and the yoke (2) in the differential support.
NOTE: orient the rod (3) with the outer groove (A)
directed towards the yoke (2).
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Insert the springs (4) and (8) and the spacer (9).
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SECTION 27 - REAR AXLE
Assemble the snap ring (5) with tool 380200260
(T2).
Remove tools 380200259 (T1) and 380200260
(T2).
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DIFFERENTIAL
Disassembly
Loosen and remove the screws (1).
Remove the ring gear (2).
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SECTION 27 - REAR AXLE
If necessary, replace the differential bearings.
Remove the bearing cups (3) and (4).
Remove the sleeve (5).
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SECTION 27 - REAR AXLE
Remove the pin (13), the gear (16) and the relevant
shoulder ring (17).
Remove the pins (18), the gears (20) and the relevant shoulder rings (21).
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Assembly
Assemble the O-rings (26) on the pins (25).
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SECTION 27 - REAR AXLE
Assemble the gears (20) and the relevant shoulder
rings (21). Insert pins (18) far enough to hold them.
NOTE: orient the pins with the flat side upwards.
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SECTION 27 - REAR AXLE
Lock the cover (7) with the snap ring (6).
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PINION ASSY
Disassembly
Measure the starting preload FP0 of the pinion bearings using a dynamometer whose cord is wound on
the end of the pinion shaft.
WARNING
Note value FP0 that is necessary for assembling the
bearings.
WARNING
Note value MP0 that is necessary for assembling
the bearings.
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SECTION 27 - REAR AXLE
Lock the differential assy in a vice.
Unscrew the ring nut (1) using special tools
380200268 and 380200269.
NOTE: this operation will irretrievably damage the
lock nut (1).
Remove the ring nut (1) and collect its washer (2).
Remove the bearing cups (7) and (8) from the differential support (9) using a buffer and a hammer.
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SECTION 27 - REAR AXLE
Assembly
Place the differential support (9) on a workbench.
Insert the bearing cups (7) and (8) with buffer
380200274 and a hammer.
Use a depth gauge to measure dimension X (distance between bearing axis of differential box and
leaning point of pinion head or bearing base).
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Select the shim (10) with value (S) from the range
of available shims, and fit it onto the shaft end under
the pinion head.
NOTE: orient the shim (10) with the chamfered end
towards the pinion head (3).
SHIM RANGE
Shims
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
mm (0.098) (0.102) (0.106) (0.110) (0.114) (0.118) (0.122) (0.126) (0.130) (0.134)
(in)
Q.ty
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SECTION 27 - REAR AXLE
Once you have chosen the suitable shim (10), insert
it on the pinion shaft with the chamfer against the
pinion head.
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Insert the washer (2) and tighten the new ring nut
(1) on the pinion shaft.
Lubricate the ring nut thread (1) and the supporting
face with the washer (2) with oil.
Screw in the ring nut (1) using the wrench for ring
nut 380200268 and the pinion retainer 380200269.
WARNING
The tightening torque is given by the measure of
the preload on bearings (7) and (8); gradually
tighten the ring nut (1).
NOTE: if the tightening is excessive, the spacer (6)
must be replaced and the procedure repeated.
When you check the preload, strike the pinion end
(3) with a soft hammer to favour the bearings (7)
and (8) settlement.
If the bearings have not been replaced, to measure
the preload FPm of the bearings (7) and (8), use a
dynamometer whose cord is wound on the end of
pinion shaft (3).
WARNING
Use this method only if the bearings are not to be
replaced, otherwise go to next step.
The measured value should be within the following
range:
FPm = FP0 (FP0 + 10) N
[FPm = FP0 (FP0 + 2.25) lbf]
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SECTION 27 - REAR AXLE
If the bearings have not been replaced, it is possible
to measure the rolling torque MPm of the bearings
(7) and (8), using a torque wrench and tool
380200269.
NOTE: use this method only if the bearings are not
replaced.
WARNING
All preloads must be measured without seal rings.
The measured value should be the same of the
starting:
MPm = MP0
If the bearings (7) and (8) are new, to measure the
preload FPm of the bearings, use a dynamometer
whose cord is wound on tool 380200272, inserted
on the end of pinion shaft.
WARNING
Values for new bearings.
In case you do not use the prescribed tool to measure the preload, the reference diameter is the diameter of pinion shaft splined end.
The measured value should be within the following
range:
FPm = 100 120 N
(FPm = 22.48 2.02 lbf)
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WARNING
All preloads must be measured without seal rings.
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127
TROUBLESHOOTING
FAULT
Wheel vibrations.
Tyre resistance.
POSSIBLE CAUSE
ACTION
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
Axle faulty.
Overload.
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FAULT
POSSIBLE CAUSE
ACTION
Incorrect installation.
Excessive noise.
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
Axle faulty.
Overload.
Differential locked.
Incorrect installation.
Incorrect installation.
Axle faulty.
Friction noise.
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SECTION 27 - REAR AXLE
FAULT
Outer tip of ring gear tooth is
broken.
POSSIBLE CAUSE
Excessive gear load compared to
the one expected.
Crash load.
Insufficient lubrication.
Contaminated lubricant.
ACTION
129
Contaminated lubricant.
Drive pinion teeth pitted.
Insufficient lubrication.
Machine overloaded.
Damaged vehicle.
Crash load.
Bearings worn or pitted.
Insufficient lubrication.
Contaminated lubricant.
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FAULT
Gaskets leak oil.
POSSIBLE CAUSE
ACTION
Intense use.
Intense use.
Intense use.
Insufficient lubrication.
Continuous overload.
Lubrication wrong.
Contaminated lubricant.
Intense use.
Replace bearing.
Unsuitable lubrication.
Contaminated lubricant.
Broken or bent axle beam.
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SECTION 27 - REAR AXLE
FAULT
Noise during travel.
Intermittent noise.
Constant noise.
POSSIBLE CAUSE
131
ACTION
Change lubricant.
Worn bearings.
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FAULT
Noise while bending.
POSSIBLE CAUSE
ACTION
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133
REPAIR TIMES
The times are referred to average values of maintenance performed by skilled personnel in workshops
equipped with all necessary fixtures for a proper
execution of the required works.
The repair and/or replacement times are indicated in
minutes.
We assume that the axle has already been removed
from the machine.
ASSY
Connection flange
OPERATION
TIME (minutes)
30
240
240
210
O-ring replacement (x 1)
30
50
40
90
105
60
30
180
150
Differential
240
Differential locking
30
Pinion
180
Wheel hub
Brake
Differential support
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SPECIAL TOOLS
PN CNH
DESCRIPTION
USE
380002211
Handle
380200268
Wrench
380200187
380002222
Buffer
380200269
Wrench
380200211
Buffer
380200218
Buffer
380200220
Buffer
380200272
Tool
380200273
False pinion
380200274
Buffer
380200243
Wrench
380200244
Wrench
380200245
Buffer
380200276
Buffer
380200254
Buffer
380200277
Buffer
380200255
Buffer
380200259
Plunger
380200260
Guide
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Manufacturer
Model
Maximum steering angle
Toe-in
CARRARO
26.32M
21 0-1
A1
2.750/1
6.923/1
19.038/1
Input rotation
clockwise
Dry weight
538 kg
(1186 lb)
Differential type
0.15 0.30 mm
(0.006 0.012 in)
FP = 92 138 N
(FP = 21 31 lbf)
MP = 1.6 2.4 Nm
(MP = 1.18 1.77 lbfft)
MT = (MP + 0.58) (MP + 0.87) Nm
[MT = (MP + 0.43) (MP + 0.64) lbfft]
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SERVICE BRAKE
Brake type
Brake actuation
Mineral oil
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138
Oil capacity
Oil type
Differential
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SECTION 27 - REAR AXLE
Before draining the oil from the axle body, use the
breather (3) to release any possible internal pressure.
WARNING
Risk of violent oil ejection.
WARNING
Risk of violent oil ejection.
Drain all oil.
Clean, screw and tighten the plug (2).
Fill through the hole of the plug (1).
Check the level and, if necessary, top up.
Clean, screw and tighten the plug (1).
Before draining the oil from the reduction gear, turn
the gear so that the plug (4) is in the highest possible position [position A].
Partially unscrew the plug (4) to release any possible internal pressure.
Turn the plug (4) and bring it to its lowest position
[position B].
Remove the plug and drain the oil.
Rotate again to bring the hole of the plug (4) to
check and oil filling position (position C).
Carry out the filling.
Clean, screw in and tighten the plug (4).
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SECTION 27 - REAR AXLE
DISASSEMBLY AND ASSEMBLY
Some of the following pictures could not exactly
show your axle, but the procedure is correct.
TIGHTENING TORQUES AND APPLICATION OF SEALANTS / ADHESIVES
B. Loctite 270
C. Loctite 638
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SECTION 27 - REAR AXLE
GREASE POINTS
Tecnolube POLYMER 400 grease
grease AGIP GR MU EP2
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FRONT FLANGE
Disassembly
Drain oil from the central body.
Remove the snap ring (1) from the pinion shaft (6)
and slip off the front flange (2).
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SECTION 27 - REAR AXLE
Remove the O-ring (3).
Collect the washer (4).
Assembly
Insert the washer (4) into the pinion shaft.
Assemble and lubricate the new O-ring (3).
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Assemble the front flange (2).
Assemble the snap ring (1).
Refill the central body with oil.
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SECTION 27 - REAR AXLE
STEERING CYLINDER
Disassembly
Loosen and remove the nuts (1) and (14) and slip
off the tie rods (3) and (12) from the swivel housings
(2) and (13).
WARNING
Do not damage the end of the threaded pins.
If necessary, replace the nuts (1) and (14).
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Remove the tie rods (3) and (12) from the cylinder
rods by loosening the nuts (4) and (11), then check
their conditions.
Remove the ball joints (5) and (9).
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Remove the snap rings (19) and (27) from the
steering cylinder (8).
Pull out the rod (23) as necessary to collect the cylinder head (25).
NOTE: do not extract the piston from the cylinder
(22).
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Assembly
Assemble the seal rings (24) onto the 2 heads (21)
and (25).
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SECTION 27 - REAR AXLE
Check the proper assembly of the seal rings.
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Push the cylinder heads (21) and (25) into the cylinder body (22).
Insert the 2 snap rings (20) and (26) into the relevant seats in the cylinder body (22).
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SECTION 27 - REAR AXLE
Check the correct assembly of the heads and snap
rings.
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Screw in the ball joints (5) and (10) to the ends of the
rod to the prescribed torque of 300 Nm (221 lbfft).
Screw in the nuts (4) and (11) and the tie rods (3)
and (12) to the ball joints (5) and (10).
Insert the ball joint of the tie rod (12) into its seat on
the swivel housing (13).
Screw in and tighten the nut (14) to a tightening
torque of 260 Nm (192 lbfft).
Repeat the mentioned operations on the other side.
Screw in the nuts (4) and (11) of the tie rods (3) and
(12) only after the toe-in adjustment has been carried out.
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Assemble the sensor (17) and the connector
bracket (16) with the clamps (15) and (18) to the
steering cylinder (8).
Tighten the clamps (7) and (8) only after the toe-in
adjustment has been carried out.
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WARNING
The steering sensor adjustment operations can be
carried out only after toe-in adjustment has been
carried out.
Connect, by means of the relevant connector (C),
the steering sensor (17) to a control device that can
detect the presence of voltage generated by the
sensor. The tool is usually provided with a led that
turns on only when voltage is present.
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SECTION 27 - REAR AXLE
Slide horizontally the steering sensor till the led is
on (position A) and measure XA dimension,
between the differential support and the rear part of
the sensor shown in the figure.
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SECTION 27 - REAR AXLE
REDUCTION GEAR
Disassembly
Unscrew the plug (1) and drain oil from the reduction gear.
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Assembly
Collect all reduction gear parts: the gear carrier, the
thrust washers (4), the gears (6) with the relevant
needle bearings (5), the washers (7) and the
screws (8).
With new gears (6), it is advisable to assemble new
bearings (5).
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Assemble the washers (7) into the pins of the planetary gear carrier (3).
Screw in and tighten the screws (8) to a tightening
torque of 79 Nm (58 lbfft).
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WHEEL HUB
Disassembly
Insert a lever between the swivel housing and the
axle body and fit it into the double joint.
With the lever push the double joint in the direction
of the wheel hub to allow the snap ring removal.
Do not damage the double joint.
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SECTION 27 - REAR AXLE
Remove the snap ring (1).
Collect the washer (2) and the thrust washer (3).
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SECTION 27 - REAR AXLE
Unscrew and remove the screws (15) and (19) from
the upper (16) and lower (18) king pins.
DANGER
Before removing the king pins (16) and (18), secure
the swivel housing (14) with a rope or a hoist or any
other supporting device to guarantee operators
safety.
Remove the king pins (16) and (18).
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Assembly
If previously removed, assemble the steering stop
screw (23), the nut (22) and the bushings (20) and
(21).
Do not tighten the nut (22) until the steering angle
adjustment has been carried out.
Insert the bronze bushing (24) into the swivel housing (14) by means of tool 380000024 and a hammer.
Assemble the new seal ring (25) into the swivel
housing (14) with tool 380200266 and a hammer.
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Assemble the lower (18) and the upper (16) king
pins.
Screw in and tighten the screws (19) and (15) to the
prescribed torque of 300 Nm (221 lbfft).
Make sure that the belleville washers stay in the
correct position.
Insert the bearing cups (9) and (12) into the wheel
hub (11) by means of tool 380200211 and a press.
Insert the new seal ring (13) into the wheel hub (11)
using tool 380200210 and a hammer.
Lubricate the seal ring (13).
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SECTION 27 - REAR AXLE
Insert a lever between the swivel housing (14) and
the axle body and fit it into the double joint.
With the lever push the double joint in the direction
of the wheel hub to allow the snap ring introduction.
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BEAM ASSY
Disassembly
Drain axle oil completely.
Loosen and remove the two screws (13).
Unscrew the nuts (11) of the oil recirculation line
(12).
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Remove the oil recirculation line (12).
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SECTION 27 - REAR AXLE
Assembly
Cool down the bushing (5) and the cup (6) to a temperature lower than -100 C (-148 F) with liquid
nitrogen.
Assemble the bushing (5) in the upper king pin seat
with buffer 380200196 and a hammer.
Assemble the cup (6) on the lower king pin seat
with buffer 380200196 and a hammer.
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SECTION 27 - REAR AXLE
Assemble the oil recirculation line (12).
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BRAKES
Disassembly
Remove the beam and the axle shaft.
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SECTION 27 - REAR AXLE
Remove the brake components: the counterdiscs
(11), discs (12), the brake disc carrier hub (10), the
brake disc (9) and the brake counterdisc (8).
NOTE: mark the position of the hub for assembly.
Remove the brake piston return kit (7) and the selfadjust kit (6).
Take out the brake piston (4) from the brake cylinder (1).
If necessary, remove the plug (14) and the relevant
O-ring (13).
Blow some air through the oil supply hole for the
brake to eject the piston (4), using the minimum
pressure required.
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Remove the O-rings (2) and (3) from the piston (4).
If necessary, remove the bushings (5) of the selfadjust kit from the piston (4), using tool 380200194
and a hammer.
Assembly
Collect the piston (4).
Push the washers (5) into the self-adjust seats
using tool 380200194 and a hammer, till they are
aligned with the piston supporting inner surface.
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Assemble the new O-rings (2) and (3) into the piston (4).
Lubricate the O-rings.
Insert the big spring, the small spring and the bushing of the piston return kit (7) into the bigger hole of
the piston.
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SECTION 27 - REAR AXLE
Bring the piston (4) to stroke end, using tool
380200238 and a hammer.
Place the tool carefully so as not to damage the piston.
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SECTION 27 - REAR AXLE
Remove the brake components: the counterdiscs
(11), discs (12), the brake disc carrier hub (10), the
brake disc (9) and the brake counterdisc (8).
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Reassemble all brake elements: the brake counterdisc (8), the brake disc (9), the brake disc carrier
hub (10), the counterdiscs (11) and the discs (12).
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DIFFERENTIAL SUPPORT
Disassembly
Remove the brake.
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SECTION 27 - REAR AXLE
Unscrew and remove the ring nut (8) from the brake
cylinder (6) using tool 380200209.
Pull out the bearing cup (5) from the brake cylinder
(6) using a buffer and a hammer.
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Assembly
Before assembling the differential, install the pinion
assy.
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SECTION 27 - REAR AXLE
Lubricate or assemble a new O-ring (4) into the seat
of the 2 brake cylinders (6).
Assemble the right brake cylinder (6) into the central body (1).
Check that the reference marks applied during disassembly between the brake cylinders and the central body coincide.
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SECTION 27 - REAR AXLE
Adjust the ring nuts (8) remembering that:
- if the measured backlash is higher than the prescribed tolerance range, tighten the ring nut on
the opposite side of the ring gear and loosen the
opposite ring nut by the same measure (A);
- if the measured backlash is lower than the prescribed tolerance range, tighten the ring nut on
the ring gear side and loosen the opposite ring nut
by the same measure (B).
WARNING
All preloads must be measured without seal ring.
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WARNING
All preloads must be measured without seal rings.
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SECTION 27 - REAR AXLE
If the measure is not within the requested range,
check the assembly of each single component and
operate on the ring nuts of the differential support:
- if the total preload is less than the given range,
screw on the adjusting ring nuts by the same
measure, keeping the pinion-ring gear backlash
value (A) unchanged;
- if the total preload is more than the given range,
unscrew the adjusting ring nuts by the same
measure, keeping the pinion-ring gear backlash
value (B) unchanged.
Once all adjustment operations have been performed, assemble the ring nut retainers (9), fastening them with the relevant screws (10).
Tighten the screws (10) to a tightening torque of
13 Nm (9 lbfft).
Turn the ring nuts (8) as little as possible to allow
their assembly.
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194
NON-SELF-LOCKING DIFFERENTIAL
Disassembly
Lock the differential with a clamp.
Loosen the screws (1) and remove the ring gear (2).
This operation releases also the two half boxes of
the differential.
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SECTION 27 - REAR AXLE
Disassemble the 2 half boxes (4) and (12).
Apply reference marks on the 2 half boxes before
separating them.
Disassemble all parts and check their operating status and wear condition.
Take out the bearings (3) and (13) from the half
boxes (4) and (12) using a puller.
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196
Assembly
Assemble the bearings (3) and (13) on the half
boxes (4) and (12), using tool 380200188 and a
hammer.
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SECTION 27 - REAR AXLE
LIMITED SLIP DIFFERENTIAL
Disassembly
Lock the differential with a clamp.
Loosen the screws (1) and remove the ring gear (2).
This operation releases also the two half boxes of
the differential.
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198
Take out the bearings (3) and (13) from the half
boxes (4) and (12) using a puller.
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SECTION 27 - REAR AXLE
Assembly
If previously removed, insert bushings (14) into the
half boxes (4) and (12) using tool 380200205 and a
hammer.
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200
PINION
Disassembly
Remove the differential assy.
Measure the starting preload FP0 of the pinion bearings using a dynamometer whose cord is wound on
the end of the pinion shaft.
WARNING
Note value FP0 that is necessary for assembling the
bearings.
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SECTION 27 - REAR AXLE
Tap the shaft end with a soft hammer to remove the
pinion (1).
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202
Assembly
Position the axle central body onto a workbench.
Insert the bearing cups (3) and (8) into their seats
using kit 380200216.
Use the false pinion 380200202 and false differential box 380200217.
Insert the bearing and the false pinion into the
seats.
Tighten the ring nut, until the backlash is eliminated.
Check the correct place of the differential box supports at the right and left side, using the reference
marks applied on the same and on the central body.
Assemble the 2 brake cylinders, fastening them
with the relevant screws.
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SECTION 27 - REAR AXLE
Insert the false differential box 380200217 into the
central axle body.
Check that the false differential box is inserted in
both seats of the differential supports.
Choose the shim with value (S) from the shim range
available.
SHIM RANGE
Shims
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
mm
(0.098) (0.102) (0.106) (0.110) (0.114) (0.118) (0.122) (0.126) (0.130) (0.134)
(in)
Q.ty
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204
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SECTION 27 - REAR AXLE
Insert the preassembled pinion (1) into the central
body and the bearing (8) into the pinion shaft.
Assemble the bearing (8) with tool 380200190 and
a hammer.
WARNING
Use this method only if the bearings are not
replaced.
The measured value should be within the following
range:
FPm = FP0 (FP0 + 10) N
[FPm = FP0 (FP0 + 2.25) lbf]
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206
In case you do not use the prescribed tool to measure the preload, the reference diameter is the diameter of pinion shaft splined end.
The measured value should be within the following
range:
FPm = 92 138 N
[FPm = 20.68 31.02 lbf]
WARNING
All preloads must be measured without seal rings.
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SECTION 27 - REAR AXLE
The measured value MP should be within this
range:
MP = 1.6 2.4 Nm
[MP = 1.18 1.77 lbfft]
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208
Toe-in check
Assemble 2 identical, 1 m long linear bars on the
wheel sides and lock them with 2 nuts on the wheel
hub stud screws.
WARNING
The 2 bars should be fixed on their middle so that
they are perfectly perpendicular to the supporting
surface and parallel to the pinion axis; align the 2
bars.
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SECTION 27 - REAR AXLE
Check that the difference between the measurements at the ends of the wheel hub diameters is
within the required tolerance range.
The nominal toe-in (A) value is referred to the external diameter of the wheel hubs flange, therefore the
measured toe-in value (M) at the bar ends must be
related to the ratio between length of the bar and
flange diameter:
nominal toe-in = A1
measured toe-in = M3
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210
In order to set the steering angle, adjust a goniometer according to the angle measure (C), calculated
as follows:
C = 90 - S
Where (S) is the prescribed steering angle set.
Place the goniometer on the long bar.
Orient the left wheel assy until the calculated angle
(C) is obtained between the two bars.
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SECTION 27 - REAR AXLE
Completely steer to the opposite side and repeat
the same operations described previously.
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212
SPECIAL INTERVENTIONS
WARNING
Do not hit the end of the threaded pin of the tie rod
(3) during disassembly.
Do not unscrew the tie rod (3) and the relevant nut
(4) so as not to impair the wheel toe-in.
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SECTION 27 - REAR AXLE
Ensure the swivel housing to a lifting device with a
rope.
Unscrew and remove the screws (5) and (9) from
the upper (6) and lower (10) king pins.
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214
Insert the ball joint of the tie rod (3) into its seat on
the swivel housing (1) by turning the swivel housing
as much as necessary.
Do not unscrew the tie rod (3) and the relevant nut
(4) so as not to impair the wheel toe-in.
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SECTION 27 - REAR AXLE
Screw in and tighten the nut (2) to a tightening
torque of 260 Nm (192 lbfft).
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216
Check the correct place of the seal ring (11) according to the axle type.
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SECTION 27 - REAR AXLE
Replacement of the bronze bushing of the double joint
Remove the wheel assy and the double joint.
Extract the seal ring (11).
Remove the bronze bushing (13) with a puller, paying attention not to damage its seat.
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218
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SECTION 27 - REAR AXLE
219
TROUBLESHOOTING
FAULT
Wheel vibrations.
Tyre resistance.
POSSIBLE CAUSE
ACTION
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
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220
FAULT
Excessive noise.
Friction noise.
POSSIBLE CAUSE
ACTION
Incorrect installation.
Axle faulty.
Overload.
Incorrect installation.
Axle faulty.
Overload.
Differential locked.
Incorrect installation.
Incorrect installation.
Axle faulty.
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SECTION 27 - REAR AXLE
FAULT
Outer tip of ring gear tooth is
broken.
POSSIBLE CAUSE
Excessive gear load compared to
the one expected.
Gear adjustment wrong (excessive
backlash).
Pinion nut loose.
Insufficient lubrication.
Contaminated lubricant.
ACTION
Crash load.
221
Contaminated lubricant.
Drive pinion teeth pitted.
Insufficient lubrication.
Machine overloaded.
Damaged vehicle.
Crash load.
Bearings worn or pitted.
Insufficient lubrication.
Contaminated lubricant.
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222
FAULT
Gaskets leak oil.
POSSIBLE CAUSE
ACTION
Intense use.
Intense use.
Intense use.
Insufficient lubrication.
Continuous overload.
Lubrication wrong.
Contaminated lubricant.
Intense use.
Replace bearing.
Unsuitable lubrication.
Contaminated lubricant.
Broken or bent axle beam.
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SECTION 27 - REAR AXLE
FAULT
POSSIBLE CAUSE
223
ACTION
Change lubricant.
Worn bearings.
Intermittent noise.
Constant noise.
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224
FAULT
Noise while bending.
POSSIBLE CAUSE
ACTION
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SECTION 27 - REAR AXLE
225
REPAIR TIMES
The times are referred to average values of maintenance performed by skilled personnel in workshops
equipped with all necessary fixtures for a proper
execution of the required works.
The repair and/or replacement times are indicated in
minutes.
We assume that the axle has already been removed
from the machine.
ASSY
Flange
Steering cylinder
Wheel hub
Axle shaft
Brake
Differential support
OPERATION
TIME (minutes)
30
Rod replacement (x 1)
30
15
30
15
15
Sensor replacement
15
120
240
60
20
35
45
30
75
90
70
30
60
30
45
30
45
45
60
120
O-ring replacement (x 1)
30
60
90
60
90
30
150
120
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226
ASSY
Differential
Pinion
OPERATION
TIME (minutes)
Differential replacement
150
240
120
180
240
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SECTION 27 - REAR AXLE
227
SPECIAL TOOLS
PN CNH
DESCRIPTION
USE
380002211
Handle
380000021
Wrench
380200188
Buffer
380200190
Buffer
380000020
Wrench
380200192
Buffer
380200194
Buffer
380200195
Buffer
380200196
Buffer
380000024
Buffer
380200202
False pinion
380200205
Buffer
380200209
Wrench
380200210
Buffer
380200211
Buffer
380200216
Kit
380200217
380200218
Buffer
380200222
Tool
380200227
Buffer
380002226
Buffer
380200237
Tool
Preload measure
380200238
Buffer
380200266
Buffer
380200267
Buffer
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228
NOTES:
Copyright
580T
580ST
590ST
695ST
Copyright
2
Copyright
SECTION 33 - BRAKE SYSTEM
PARKING BRAKE
This device allows the immobilization of the
machine each time it must be parked or stopped to
carry out maintenance work.
TECHNICAL SPECIFICATIONS
Type ....................................................................................................................................... manual, with lever
Maximum lever pull ....................................................................................................................1650 N (371 lbf)
Lever stroke ............................................................................................................................... 21 mm (0.87 in)
Maximum torque - Powershuttle ..........................................................................................2000 Nm (450 lbfft)
Maximum torque - Powershift ..............................................................................................1500 Nm (337 lbfft)
OPERATION
The parking brake essentially consists of:
- manual control lever;
- transmission brake.
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4
ADJUSTMENT
The parking brake can be adjusted by placing the
brake pad in contact with the disc, now you have to
block the brake cable.
The brake cable movement (1) can be adjusted by
handling on the locknut (2).
Adjust the parking brake so as to brake the machine
completely by lifting the brake lever up to the 4th
ratchet.
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SECTION 33 - BRAKE SYSTEM
DISASSEMBLY AND ASSEMBLY
These procedures deal with the parking brake section and leave off the control lever and the relevant
connection cable.
1. Screw
10. Piston
2. Washer
3. O-ring
12. O-ring
4. Flange
5. Screw
14. O-ring
6. Brake cover
15. Disc
7. O-ring
8. Belleville washer
17. Hub
9. O-ring
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6
DISASSEMBLY
Loosen the screw (1).
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SECTION 33 - BRAKE SYSTEM
Remove all screws (5), the screws (A) and alternately loosen the screws (B) to release the load
from the belleville washers.
NOTE: the housing is under spring pressure, failure
to follow the instructions will result in serious injury
or damage to the equipment.
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SECTION 33 - BRAKE SYSTEM
Remove the O-ring (9) from the piston (10).
INSPECTION
Clean all parts in cleaning solvent.
Inspect the brake discs and plates for pitting, scoring, excessive surface wear and other damage.
Inspect the belleville washer for cracking and excessive surface wear at contact points.
Inspect brake pistons and housing for scratches on
their sliding surfaces, and contact surfaces for pitting or excessive wear.
Replace the O-rings.
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10
ASSEMBLY
Assemble the new O-ring (7) on the brake cover (6).
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SECTION 33 - BRAKE SYSTEM
Compress the belleville washers, to assemble the
snap ring (11).
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12
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SECTION 33 - BRAKE SYSTEM
Screw in the screw (1) with the washer (2).
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14
SERVICE BRAKE
During operation, the brake system of the machine
can stop the machine at any time.
TECHNICAL SPECIFICATIONS
2WS
Type ........................................................................................................wet multi-discs, 4 x axle (2 x half axle)
Braking surface ..................................................................................................................... 1236 cm2 (191 in2)
4WS
Type ........................................................................................................wet multi-discs, 6 x axle (3 x half axle)
Braking surface ..................................................................................................................... 1092 cm2 (169 in2)
OPERATION
This system essentially consists of:
- brake pedals (in the cab);
- wet disc brakes hydraulically operated in the rear
axle.
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580T
580ST
590ST
695ST
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2
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SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC DIAGRAMS
HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS
WITH FIXED-FLOW-RATE GEAR PUMP
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4
1.
2.
Power steering
3.
Dipper cylinders
Boom cylinders
7.
8.
9.
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SECTION 35 - HYDRAULIC SYSTEM
WITH FIXED-FLOW-RATE GEAR PUMP - WITHOUT BACKHOE ATTACHMENT SWING CONTROL VALVE
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6
1.
2.
Power steering
3.
Dipper cylinders
Boom cylinders
7.
8.
9.
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SECTION 35 - HYDRAULIC SYSTEM
WITH VARIABLE-FLOW-RATE PISTON PUMP
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8
1.
2.
Power steering
3.
Dipper cylinders
Boom cylinders
7.
8.
9.
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SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS
WITH FIXED-FLOW-RATE GEAR PUMP
Copyright
10
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SECTION 35 - HYDRAULIC SYSTEM
WITH VARIABLE-FLOW-RATE PISTON PUMP
11
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12
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SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS
13
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14
1.
2.
3.
4.
Power steering
5.
Dipper cylinders
Boom cylinders
9.
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SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS
15
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16
1.
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SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS
17
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18
1.
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SECTION 35 - HYDRAULIC SYSTEM
19
HYDRAULIC PUMP
The machine can be provided with 2 types of
hydraulic pump:
- fixed-flow-rate gear pump;
- variable-flow-rate piston pump.
Further to the type, pumps differentiate according to
the motor:
- 72 kW (97 HP) motor;
- 82 kW (110 HP) motor.
TECHNICAL SPECIFICATIONS
Pump 72 kW - 97 HP (580T - 580ST)
Model .......................................................................................................... CASAPPA KP 30.34 - 05 S6 - LMF
Type ...................................................................................................................................... double gear pump
Displacement ............................................................................. 35.427 + 35.427 cm3/rev (2.16 + 2.16 in3/rev)
Pump 82 kW - 110 HP (590ST - 695ST)
Model .......................................................................................................... CASAPPA KP 30.38 - 05 S6 - LMF
Type ...................................................................................................................................... double gear pump
Displacement ............................................................................. 40.258 + 35.427 cm3/rev (2.45 + 2.16 in3/rev)
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20
1st PUMP
2nd PUMP
Clockwise (D)
35.427 cm3/rev
(2.16 in3/rev)
Displacement
Inlet pressure range for pump
35.427 cm3/rev
(2.16 in3/rev)
P1
P2
P3
Operating temperature
Speed
350 rpm
max P1
Viscosity range
Contamination class
3000 rpm
2
recommended
permitted
8 - Nas 1638
Relief valve
Weight
30 kg (66 lb)
1st PUMP
2nd PUMP
Clockwise (D)
40.258 cm3/rev
(2.45 in3/rev)
Displacement
Inlet pressure range for pump
35.427 cm3/rev
(2.16 in3/rev)
P1
P2
P3
Operating temperature
Speed
Viscosity range
Contamination class
Relief valve
Stand by pressure load sensing valve
Weight
350 rpm
max P1
3000 rpm
recommended
permitted
8 - Nas 1638
19 / 17 /14 - ISO 4406
10 - Nas 1638
177 3 bar (2567 - 43 psi)
7 bar (102 psi)
30 kg (66 lb)
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SECTION 35 - HYDRAULIC SYSTEM
Tightening torques
Hydraulic diagram
21
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22
LOAD-SENSING VALVE
1. Orifice
3. Filter
10. Poppet
4. Spool
6. Orifice
14. Orifice
When the steering is in neutral the LS port is connected to the unload (through the steering) and the
steering inlet port (CF) is open.
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SECTION 35 - HYDRAULIC SYSTEM
23
1.
2.
3.
4.
The pressure on (CF) increases until the pressure value (stand-by pressure) is sufficient to move the spool
valve in a way to divert the flow toward (EF).
1.
2.
3.
4.
Trapped oil
Return to oil tank
Orifice
Rear systems (EF)
Filter
Spool
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24
COMPONENTS
1. Screw
19. Bushing
20. Gasket
3. Spool
21. Bushing
4. O-ring
5. Plug
23. Bearing
6. Valve
24. Gear
7. Filter
25. Gear
8. Fitting
9. Spring seat
27. Gasket
10. Spring
28. Gear
11. O-ring
29. Flange
12. Cover
14. O-ring
15. Poppet
16. Spring
34. Gear
17. Seat
35. O-ring
36. Screw
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SECTION 35 - HYDRAULIC SYSTEM
DISASSEMBLY AND ASSEMBLY
Disassembly of the steering control valve
To aid reassembly draw an alignment line along the
total length of the pump assembly.
Remove the screws (1).
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26
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SECTION 35 - HYDRAULIC SYSTEM
Inspect the wear track cut by the gears in pump
body. The body can be reused if the track is bright
and polished and does not exceed 0.08 0.076 mm
(0.0031 0.0029 in) in depth.
Examine bearing block faces for scoring and flatness, paying particular attention to the face which
abuts the gears.
Examine bearing block bushes for scoring.
Examine pump gears for scored or worn side faces,
journals and damaged teeth.
If pump block, gears or bearing blocks are worn and
require replacement the pump assembly must be
replaced.
Re-assemble using the disassembly procedure in
reverse order and observe the following warnings:
- ensure that all parts are perfectly clean and lubricate bushes and gears with clean hydraulic fluid;
- replace all seals and O-rings;
- install the bearing blocks into the same positions
from which they were removed, using the identification letters written during disassembly;
- ensure plastic back-up seals are correctly positioned in the rubber seal.
27
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28
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SECTION 35 - HYDRAULIC SYSTEM
Assemble the inner seal, (30), with the spring and
the lip facing the pump.
Install the outer seal ring (31), with the spring and
the lip facing outwards and refit the snap ring (30).
Coat the rings with high melting point grease.
NOTE: ensure seal rings are fitted back to back.
NOTE: if the seal ring recess has been scored during seal removal, coat the outside diameter of the
seal ring with flexible gasket sealant to prevent
leakage.
29
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30
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SECTION 35 - HYDRAULIC SYSTEM
COMPONENTS
31
Copyright
32
1. Snap ring
2. Seal ring
33. Articulation
3. Pump body
34. Pin
4. O-ring
35. Cylinder
5. Plug
36. Washer
6. Plug
37. Spring
7. O-ring
38. Washer
8. Bearing
39. Ring
9. Shaft
40. Plug
41. O-ring
11. Pin
42. Spool
43. Plug
13. Pin
44. O-ring
45. Spool
15. Spring
16. Piston
47. O-ring
48. Plug
18. O-ring
19. Bearing
50. Spring
20. Pin
51. Spring
52. O-ring
23. Spring
54. Plug
24. O-ring
55. O-ring
25. Plug
26. Cover
57. Spring
27. Screw
58. Spring
28. O-ring
60. O-ring
30. Screw
31. Piston
62. Dowel
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SECTION 35 - HYDRAULIC SYSTEM
DISASSEMBLY AND ASSEMBLY
Disassembly
Remove the load-sensing control valve (29) by
removing the 4 screws (30).
Remove and discard the 4 O-rings (28).
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34
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SECTION 35 - HYDRAULIC SYSTEM
Orient the pump body (3) with the flange upwards.
Remove the snap ring (1).
Carefully pry out the seal ring (2).
In case it is not possible to extract the seal ring (2),
try to push the seal out by going through the inside
of the pump body (3).
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36
WARNING
Compressing the spring (37) requires about
350 400 N (79 90 lbf).
Use a press sufficient to maintain this force.
Ensure that the spring is secure before attempting
to remove the ring (39).
Release the pressure slowly after the ring (39) has
been removed.
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SECTION 35 - HYDRAULIC SYSTEM
Inspection
After disassembly, wash all parts (including the end
cap and the pump body) thoroughly with clean solvent and allow to air dry.
Clean the oil ducts in the pump body and the end
cover with compressed air.
Conduct inspection in a clean area and keep all
parts free from contamination.
Inspect the pistons (31) for damage and discoloration. Discoloured pistons may indicate excessive
heat; do not reuse.
Inspect the running surface of the pistons (A).
Replace all pistons with scored or excessively
rounded edges. Measure the piston foot thickness
(B). Replace all excessively worn pistons.
Check the axial end-play (C).
Replace all pistons with excessive end-play.
Foot thickness (B)
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38
Make sure that the shaft (9) and its splines are
straight and free of damage or heavy wear.
Inspect the shaft surface where it meets the seal
ring.
Replace the shaft if a groove exists at the sealing
land surface that may let dirt into or hydraulic oil out
of the unit.
Clean the sealing area with non-abrasive material.
Lubricate the shaft with a light coat of oil.
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SECTION 35 - HYDRAULIC SYSTEM
Carefully inspect each surface of the swash plate
(14) for wear. All swash plate surfaces should be
smooth.
Inspect the swash plates running surface for damage and brass transfer.
Excessive transfer may indicate that the pistons
should be replaced.
Finally, check the swash plate pin for scratches.
39
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40
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SECTION 35 - HYDRAULIC SYSTEM
Assembly
Coat the cradle bearings (10) with oil and install
them into the pump body (3).
Insert the pins (11) a minimum of 0.5 mm (0.02 in)
below the bearing surface.
If the bearings (10) are reused, reinstall them in
their original position.
Install the bearing (8).
Before replacing the spring (15), coat the contact
surface of the swash plate (14) with oil.
Assemble the swash plate (14), and the piston (16)
and the spring (15) into the pump body (3).
Rotate the piston (16) perpendicularly to the swash
plate (14) and, at the same time, compress the spring
(15) to fit it into the pump body (3).
Liberally lubricate all sides of the piston (16) and its
relevant bore and also the flat face of the swash
plate to prevent premature wear during start-up.
Insert the shaft (9) through the bearing in the body.
Push on the piston to rotate the swash plate in order
to put the shaft in properly.
Lubricate components before assembly.
Install the inner washer (36), the spring (37) and the
outer washer (38) into the cylinder (35). Compress
the spring enough to insert the ring (39).
WARNING
Compressing the spring (37) requires about
350 400 N (79 90 lbf).
Use a press sufficient to maintain this force.
Ensure that the spring is secure before attempting
to assemble the ring (39).
Release the pressure slowly after the ring (39) has
been installed.
Turn the cylinder over and assemble the pins (34)
and the ball guide (33) into the cylinder (35).
Assemble the pistons (31) on the piston disc (32).
Install the piston/disc assy into the cylinder (35).
Ensure the concave surface of the disc seats correctly in the ball guide. If reusing the pistons, install
them to the original cylinder bores.
Lubricate the pistons (31), the piston disc (32) and
the ball guide (33) before assembly.
IMPORTANT: make sure to install the piston disc
(32) so that it mates correctly with the articulation
(33), the concave side of the disc against the convex side of the ball guide.
41
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42
Secure the end of the shaft with one hand and keep
it horizontal. Insert the cylinder assy (17) onto the
shaft (9).
While holding the shaft still, slightly rotate the cylinder assy (17) to help position the shaft splines over
the ball guide and align them with the cylinder
splines.
When the cylinder slides completely over the shaft
splines, reposition the body with the flange facing
downward.
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SECTION 35 - HYDRAULIC SYSTEM
Lubricate the seal ring (2) with oil.
Place a protective sleeve over the shaft end (9) to
prevent damage to the seal ring during installation.
Holding the seal ring (2) perpendicular to the shaft
(9), press it into the body just far enough to clear the
ring groove.
Assemble with the concave side towards the shaft
bearing.
Assemble the snap ring (1).
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44
CONTROL VALVES
The hydraulic circuit is a load-sensing flow sharing
system working together with a hydraulic pump.
This system has the advantage that at any time the
distribution of flow to the services being operated is
in proportion to the openings of the control valve
spools.
The flow distribution to the backhoe and loader
control valves is independent of the load and it is
therefore possible to operate two or more spools at
the same time.
Important components of the system are the pressure compensator valves in each control valve section, together with the load-sensing line which
connects all spools of the loader and backhoe
attachment control valves.
With the fixed-flow-rate hydraulic pump, the loadsensing line only connects the loader and backhoe
attachment control valves and does not have any
connection to the hydraulic pump.
The hydraulic pump draws oil from the tank and
flow from the front pump is directed to the centre
galleries of the loader and backhoe control valves
assemblies.
The flow coming from the rear section of the pump
passes through the flow divider valve and sends
the priority flow to the steering system, while the
remaining flow adds to the flow from the front
pump, directed to the loader and backhoe attachment systems.
The centre gallery of both the loader and backhoe
control valves are blocked by the end plate.
Pressure in the supply system is controlled by the
pump flow balancer valve in accordance with the
pressure in the load-sensing line.
Consequently, the higher the load sensing pressure
is, the less flow is returned to the tank, with a corresponding increase in flow/pressure to the hydraulic
systems.
Maximum system pressure is limited by the load
sense pressure relief valve which relieves pressure in
the load sense line when it reaches 210 bar (304 psi).
Since the flow balancer valve is influenced by the
load-sensing pressure, the valve diverts a sufficient
quantity of oil to the tank to maintain the maximum
system pressure of 210 bar (304 psi).
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SECTION 35 - HYDRAULIC SYSTEM
SYSTEM DIAGRAM (BACKHOE ATTACHMENT MECHANICAL CONTROLS)
Suction oil
2. Hydraulic pump
9. Backhoe hammer
3. Power steering
5. Hand hammer
12. Filter
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Suction oil
1. Hydraulic tank
9. Backhoe hammer
2. Pump
3. Power steering
12. Filter
5. Hand hammer
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SECTION 35 - HYDRAULIC SYSTEM
OIL FLOW OPERATION
All loader/backhoe attachment systems are in
neutral position
Each control valve section within the backhoe or
loader control valve assemblies contains a spool,
two check valves and a load-sensing pressure compensator.
A load-sensing gallery connects the compensators
in each control valve section.
When all control valves are in neutral position, the
spools stop the oil flow in each system and the pressure of the load-sensing line can bleed to the tank
through the relevant return-to-tank port.
Because there is no load sense pressure being
applied to the rear face of the flow balancer valve,
the valve will move against the spring and off its
seat when pump pressure reaches 15 bar. The
pump flow is now diverted back to the tank and the
balancer valve maintains a stand-by pressure of 15
bar while the systems are in neutral position.
2. Load-sensing limiter
(system pressure relief valve)
6. Pump flow IN
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Trapped oil
1. Load non-return check valve
3. Pressure compensator
4. Spool
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SECTION 35 - HYDRAULIC SYSTEM
49
2. Load-sensing limiter
(system pressure relief valve)
6. Pump flow IN
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50
3. Pressure compensator
4. Spool
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SECTION 35 - HYDRAULIC SYSTEM
51
6. Pump flow IN
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52
Trapped oil
3. Pressure compensator
4. Spool
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SECTION 35 - HYDRAULIC SYSTEM
LOADER CONTROL VALVE
The loader control valve is mounted on the right side
of the machine adjacent to the pump.
This control valve may be of 2 types, similar to each
other, according to the hydraulic pump assembled to
the machine:
- gear pump (with fixed flow rate);
- piston pump (with variable flow rate).
The control valve consists of 2 or 3 sections, an end
cover and an inlet section.
The 3 control valve sections are:
- loader attachment lifting;
- loader bucket;
- 4x1 loader bucket.
The loader attachment control valve has three sections when the 4x1 bucket is installed on the
machine.
LOADER ATTACHMENT CONTROL VALVE WITH GEAR PUMP (WITH FIXED FLOW RATE)
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LOADER ATTACHMENT CONTROL VALVE WITH PISTON PUMP (WITH VARIABLE FLOW RATE)
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SECTION 35 - HYDRAULIC SYSTEM
CONTROL VALVE REMOVAL FROM MACHINE
Move the machine to a level and firm ground, away
from any soft ground, excavations and poorly
shored cavity.
Lower the loader attachment to the ground.
Place the direction-of-travel lever and gearshift lever
in neutral position.
Immobilize the machine by means of the parking
brake.
Lower the stabilizers to the ground.
Stop the engine and remove the starter key.
Release the hydraulic pressure by operating the
control levers in all directions.
On hydraulically controlled machines, turn the key
to ON and release the pressure by moving the
hydraulic control levers in all directions.
Place some wedges under the wheels so as to prevent the machine from moving.
Disconnect the electric system by disconnecting the
battery master switch.
Drain oil from the hydraulic system.
Disconnect the battery.
Clean the area around the control valve.
Identify and disconnect the articulations, cables and
hoses and plug the hose ends.
A drip tray will be required to catch oil draining from
inside the hoses.
Loosen and remove the fastening screws.
Remove the control valve assembly from the
machine.
For installation, follow the removal procedure in
reverse order.
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DISASSEMBLY
Loosen and remove the 3 nuts (1).
[Tightening torque = 27 2 Nm (19.91 1.47 lbfft)]
Extract the 3 tie rods (2).
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SECTION 35 - HYDRAULIC SYSTEM
BACKHOE ATTACHMENT CONTROL VALVE
The backhoe attachment control valve is located in
the rear part of the machine.
The backhoe attachment control valve may be of 2
types, similar to each other, according to the
hydraulic pump installed on the machine:
- gear pump (with fixed flow rate);
- piston pump (with variable flow rate);
Furthermore, the backhoe attachment control valves
are divided into:
- control valves for backhoe attachment mechanical
controls;
- control valves for backhoe attachment pilot controls.
The backhoe attachment control valve may consist
of 6 or 7 or 8 sections, an end cover and an inlet
section.
The possible 8 sections are:
- right-hand stabilizer;
- left-hand stabilizer;
- boom;
- digging;
- swing;
- bucket;
- telescopic dipper (optional);
- auxiliary attachment (only optional on control
valves for backhoe attachment pilot controls).
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1. End cover
2. Inlet section
C. Dipper section
D. Bucket section
E. Swing section
F. Boom section
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SECTION 35 - HYDRAULIC SYSTEM
59
1. End cover
2. Inlet section
C. Dipper section
D. Bucket section
E. Swing section
F. Boom section
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SECTION 35 - HYDRAULIC SYSTEM
DISASSEMBLY AND ASSEMBLY
Loosen and remove the 3 nuts (1).
[Tightening torque = 27.2 Nm (20.06 lbfft)]
Extract the 3 tie rods (2).
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- loosen and remove the yoke (30) with the protection (31);
[Tightening torque = 10 Nm (7.4 lbfft)]
- loosen and remove the screws (32);
[Tightening torque = 10 Nm (7.4 lbfft)]
- remove the flange (33) with the relevant seal
(34);
- keep the seal (35);
- extract the spool (36).
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SECTION 35 - HYDRAULIC SYSTEM
Assembly of spool seals
Position the metal part of the seal (29) on the outside of the spool (36).
The seal must be fitted on the end of the spool so
that its grooves (S) are not damaged and its tightness is not jeopardized.
Let the seal slide perpendicularly onto the spool.
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SECTION 35 - HYDRAULIC SYSTEM
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SECTION 35 - HYDRAULIC SYSTEM
DISASSEMBLY AND ASSEMBLY
Loosen and remove the 3 nuts (1).
[Tightening torque = 27.2 Nm (20.06 lbfft)]
Extract the 3 tie rods (2).
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SECTION 35 - HYDRAULIC SYSTEM
RELIEF VALVES
There are different relief valves installed on the
loader and backhoe attachment control valves.
The relief valves may be operated with anti-cavitation feature (1) or direct acting (2) and protect the
single systems from excessive pressure.
OPERATION
Relief valve inoperative
When the system is not subject to overload conditions pressure in the system is insufficient to overcome pilot valve spring pressure and move the
valve of its seat.
System pressure sensed on the larger rear face of
the poppet valve maintains the poppet and sleeve
firmly on their seats.
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
6. Control valve (cylinder) exhaust gallery
7. Cylinder supply gallery
Exhaust oil
High pressure oil
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Exhaust oil
High pressure oil
Reduced pressure oil
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SECTION 35 - HYDRAULIC SYSTEM
Anti-cavitation operation
Relief valves with an anti-cavitation feature are fitted
in systems where a rapid extension of the cylinder
could create a void condition and permit the transfer
of oil from the high pressure side of a cylinder to the
low pressure (void) side.
When for example the boom is rapidly lowered and
the cylinder rod end circuit relief valve operates, oil
has been removed from the rod end of the cylinder
and a void created in the piston end. This oil is automatically replenished by the anti-cavitation device in
the opposite circuit relief valve as follows:
The void creates a pressure lower in the cylinder
supply gallery and back pressure in the control
valve exhaust gallery acts on the outer face of the
sleeve poppet moving it to the right.
Exhaust oil is then directed into the cylinder supply
gallery to stop cavitation.
2. Cylinder rod
5. Spool
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Pilot-operated pressure relief valve with anti-cavitation feature subjected to overload and fully relieving
high-pressure oil
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
6. Control valve (cylinder) exhaust gallery
7. Cylinder supply gallery
Anti-cavitation cylinder resupply oil
Exhaust oil
Direct-acting pressure relief valve operation
High-pressure oil in the system is sensed in the cylinder supply gallery and acts on the surface of the
pressure relief valve poppet.
When pressure in the system exceeds the pressure
relief valve setting, the oil pressure lifts the poppet,
allowing excess pressure in the overloaded cylinder
to escape to the drain gallery.
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SECTION 35 - HYDRAULIC SYSTEM
OVERHAUL
Before removing the relief valves from the machine,
lower the loader and backhoe attachment to the
ground, stop the engine and relieve pressure in all
systems by moving the backhoe attachment, loader
attachment and telescopic dipper controls through
all operating positions. If the pressure relief valves
are suspected of contamination, they may be disassembled and inspected for wear. During assembly,
restore the correct pressure.
During disassembly examine the poppet and seat in
the plunger assembly for a complete seating surface.
Pilot operated relief valve
1. Body
9. O-ring
2. Shutter
10. Nut
3. Spring
11. O-ring
4. Spring
5. O-ring
13. Spring
6. O-ring
7. Valve
15. Poppet
8. Cover
16. Piston
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1. Body
6. Cover
2. Poppet
7. O-ring
3. Spring
8. Nut
4. Spring
9. O-ring
5. Shim
7. Piston
3. Nut
8. Poppet
4. Body
9. Valve
5. Adjusting screw
6. Spring
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SECTION 35 - HYDRAULIC SYSTEM
ADJUSTMENTS
System pressure relief valve adjustment
After overhaul, the pressure relief valves of the system must be tested and adjusted using a suitable
hand pump (1), a 275 bar (3988 psi) pressure
gauge and a V. L. Churchill test kit (2).
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SECTION 35 - HYDRAULIC SYSTEM
Reassemble the valve and install it on the test block.
Operate hand pump and recheck pressure.
If pressure is now lower than that recorded with the
insert installed it is an indication that the anti-cavitation feature of the valve is leaking and the valve
requires overhaul or replacement.
The insert isolates the anti-cavitation feature of the
valve. When reassembling the insert into the test
block ensure it is installed correctly. When correctly
installed the O-ring (3) on the face of the insert
should be visible.
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SECTION 35 - HYDRAULIC SYSTEM
If the backhoe loader is equipped with a telescopic
dipper and if the rear control valve contains an auxiliary section, the solenoid valve consists of valve
(B) and module (C).
DISASSEMBLY
Unscrew and remove the accumulator (1) from the
solenoid valve assy (2).
Loosen and remove the three screws (3) and disassemble valve (4).
Check and replace the O-rings (5), if necessary.
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SECTION 35 - HYDRAULIC SYSTEM
81
MAINTENANCE
SAFETY
Regularly check the gas pre-charge pressure during the first few weeks of operation.
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SECTION 35 - HYDRAULIC SYSTEM
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SECTION 35 - HYDRAULIC SYSTEM
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2. Limiter
6. Compressor rod
3. Cushioning rod
7. Limiter
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SECTION 35 - HYDRAULIC SYSTEM
87
HYDRAULIC CYLINDERS
7. Telescopic cylinder
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88
1. Stroke
2. Completely retracted
2WS-TC
1. Stroke
2. Completely retracted
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SECTION 35 - HYDRAULIC SYSTEM
LOADER ATTACHMENT BOOM CYLINDER REMOVAL
Move the machine to a level and firm ground.
Sufficiently raise the loader attachment to allow the
boom cylinder pivot pin to be removed and securely
support the front and rear part of the bucket with
stands to prevent the loader attachment arms from
lowering when the cylinder is disconnected.
If the bucket cannot be safely supported, remove it
and support the loader attachment arms using a
suitable stand or hoist.
WARNING
Always ensure that the loader is fully supported. Do
not work under or near an unsupported loader
attachment, to prevent the danger of personal
injury.
Relieve the residual pressure in the system by moving the loader control lever through all operating
positions.
Stop the engine.
Support the cylinder using sling and suitable hoist.
Disconnect the hoses.
Cap or plug all exposed openings.
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SECTION 35 - HYDRAULIC SYSTEM
LOADER ATTACHMENT BOOM CYLINDER DISASSEMBLY
1. Cylinder rod
9. Back-up ring
2. Bushing
10. O-ring
3. Wiper ring
11. Piston
4. Ring
5. Seal ring
6. Guide bush
14. Screw
7. Cylinder head
8. Safety screw
16. Bushing
WARNING
Cylinder weight (2WS): 32.5 kg (71.65 lb).
Cylinder weight (4WS): 41.3 kg (91.05 lb).
Lift and securely place the cylinder on a workbench.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.
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Remove the cylinder head (7) from the cylinder barrel (15) using a plastic hammer.
Remove the cylinder rod (1) and the cylinder head (7).
IMPORTANT: be sure to pull the cylinder rod (1)
straight so as not to damage the sliding surfaces.
Only if necessary:
- remove the wiper ring (3), the seal ring (4), the
ring (5), the guide bush (6) and the back-up ring
(9) with the O-ring (10) from the cylinder head (7);
- remove the piston seal (12) and the piston guide
rings (13) from the piston (11).
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SECTION 35 - HYDRAULIC SYSTEM
LOADER BUCKET CYLINDER
2WS
1. Stroke
2. Completely retracted
4WS
1. Stroke
2. Completely retracted
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SECTION 35 - HYDRAULIC SYSTEM
LOADER BUCKET CYLINDER DISASSEMBLY
1. Bushing
9. O-ring
2. Cylinder rod
10. Piston
3. Wiper ring
4. Seal ring
5. Ring
13. Screw
6. Cylinder head
7. Snap ring
15. Bushing
8. Back-up ring
WARNING
Cylinder weight: 32.5 kg (71.65 lb).
Lift and securely place the cylinder on a workbench.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.
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Only if necessary:
- remove the wiper ring (3), the seal ring (4), the
ring (5), the back-up ring (8) with the O-ring (9)
from the cylinder head (6);
- remove the piston seal (11) and the piston guide
ring (12) from the piston (10).
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SECTION 35 - HYDRAULIC SYSTEM
4X1 LOADER BUCKET CYLINDER
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Unscrew and remove the nut (6) and the dowel (5).
Slide out the lower pin (7) with an hammer.
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SECTION 35 - HYDRAULIC SYSTEM
LOADER 4x1 BUCKET CYLINDER DISASSEMBLY
1. Cylinder tube
7. Cylinder head
2. Piston
8. Gasket
3. Pin
9. Wiper ring
4. O-ring
5. Piston guide
11. Bushing
6. O-ring
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1. Stroke
590ST - 695ST
2. Completely retracted
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Stop the engine and move the backhoe attachment
control levers through all operating positions to
relieve any residual pressures in the system.
Position a sling or other suitable lifting equipment
around the cylinder.
580T - 580ST
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SECTION 35 - HYDRAULIC SYSTEM
Disconnect the hoses (T).
Cap or plug all exposed openings.
Remove the snap ring (1) and the spacers (2).
Extract the pin (3) with a hammer.
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1. Wiper ring
2. Bushing
11. O-ring
3. Cylinder rod
4. Wiper ring
5. Seal ring
14. Piston
6. Ring
15. Screw
7. Guide bush
8. Screw
17. Bushing
9. Cylinder head
WARNING
Cylinder weight (580T - 580ST): 92.7 kg (204.36 lb).
Cylinder weight (590ST - 695ST): 106 kg (233.69 lb).
Lift and securely place the cylinder on a workbench.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.
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SECTION 35 - HYDRAULIC SYSTEM
Support the cylinder rod (3).
Unscrew and remove the safety screw (8).
Use wrench 380000724 to loosen the cylinder
head (9).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.
Only if necessary:
- remove the wiper ring (4), the seal ring (5), the ring
(6), the guide bush (7) and the back-up ring (10)
with the O-ring (11) from the cylinder head (9);
- remove the piston guide ring (13) and the piston
seal (12) from the piston (14).
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1. Stroke
590ST - 695ST
2. Completely retracted
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Stop the engine and move the backhoe attachment
control levers through all operating positions to
relieve any residual pressures in the system.
Position a sling or other suitable lifting equipment
around the cylinder.
580T - 580ST
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SECTION 35 - HYDRAULIC SYSTEM
Check that the dipper (A) and the boom (B) are in a
safe position to prevent involuntary movements
after the removal of the dipper cylinder (1).
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1. Wiper ring
2. Bushing
11. O-ring
3. Cylinder rod
4. Wiper ring
5. Seal ring
14. Piston
6. Ring
15. Screw
7. Guide bush
8. Safety screw
17. Bushing
9. Cylinder head
WARNING
Cylinder weight (580T - 580ST): 73.4 kg (161.82 lb).
Cylinder weight (590T - 695ST): 74.6 kg (164.46 lb).
Lift and securely place the cylinder on a workbench.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.
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SECTION 35 - HYDRAULIC SYSTEM
Support the cylinder rod (3).
Unscrew and remove the safety screw (8).
Loosen the cylinder head (9).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.
Only if necessary:
- remove the wiper ring (4), the seal ring (5), the
ring (6), the guide bush (7) and the back-up ring
(10) with the O-ring (11) from the cylinder head
(9);
- remove the piston guide ring (13) and the piston
seal (12) from the piston (14).
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1. Stroke
580T - 580ST
2. Completely retracted
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Stop the engine and move the backhoe attachment
control levers through all operating positions to
relieve any residual pressures in the system.
Position a sling or other suitable lifting equipment
around the cylinder.
Remove the snap ring (1) and the spacer (2).
Extract the pin (3) with a hammer and pay attention
to bucket levers.
If necessary use hydraulic power to very slowly
retract the cylinder.
590ST - 695ST
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SECTION 35 - HYDRAULIC SYSTEM
Disconnect the hoses (T).
Cap or plug all exposed openings.
Remove the snap ring (4) and the spacer (5).
Extract the pin (6) with a hammer.
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1. Wiper ring
2. Bushing
11. O-ring
3. Cylinder rod
4. Wiper ring
5. Seal ring
14. Piston
6. Ring
15. Screw
7. Guide bush
8. Safety screw
17. Bushing
9. Cylinder head
WARNING
Cylinder weight (580T - 580ST): 60.7 kg (133.82 lb).
Cylinder weight (590ST - 695ST): 67 kg (147.71 lb).
Lift and securely place the cylinder on a workbench.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.
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SECTION 35 - HYDRAULIC SYSTEM
Support the cylinder rod (3).
Unscrew and remove the safety screw (8).
Loosen the cylinder head (9).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.
Loosen and remove the screw (15). Extract the piston (14) and the cylinder head (9) from the cylinder
rod (3).
Only if necessary:
- remove the wiper ring (4), the seal ring (5), the
ring (6), the guide bush (7) and the back-up ring
(10) with the O-ring from the cylinder head (9);
- remove the piston guide ring (13) and the piston
seal (12) from the piston (14).
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TELESCOPIC CYLINDER
1.
Stroke
2. Completely retracted
580T - 580ST
590ST - 695ST
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SECTION 35 - HYDRAULIC SYSTEM
TELESCOPIC CYLINDER DISASSEMBLY
1. Cylinder rod
9. Back-up ring
2. Bushing
10. O-ring
3. Wiper ring
11. Piston
4. Ring
5. Seal ring
6. Guide bush
14. Screw
7. Cylinder head
8. Safety screw
16. Bushing
WARNING
Cylinder weight (580T - 580ST): 37.6 kg (82.90 lb).
Cylinder weight (590ST - 695ST): 41.9 kg (92.37 lb).
Lift and securely place the cylinder on a workbench.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.
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Only if necessary:
- remove the wiper ring (2), the seal ring (3), the
ring (4), the guide bush (5) and the O-ring (9) with
the back-up ring (8) from the cylinder head (7);
- remove the piston guide ring (11) and the piston
seal (10) from the piston (12).
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SECTION 35 - HYDRAULIC SYSTEM
STABILIZER CYLINDER - CENTER PIVOT (695ST)
(1) Stroke
(2) Completely retracted
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SECTION 35 - HYDRAULIC SYSTEM
STABILIZER CYLINDER DISASSEMBLY - CENTER PIVOT
1. Cylinder rod
8. Back-up ring
2. Wiper ring
9. O-ring
3. Ring
4. Seal ring
5. Guide bush
12. Piston
6. Safety screw
13. Screw
7. Cylinder head
WARNING
Cylinder weight: 43.4 kg (95.68 lb).
Lift and securely place the cylinder on a workbench.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.
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Only if necessary:
- remove the wiper ring (2), the seal ring (3), the
ring (4), the guide bush (5) and the O-ring (9) with
the back-up ring (8) from the cylinder head (7);
- remove the piston guide ring (11) and the piston
seal (10) from the piston (12).
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SECTION 35 - HYDRAULIC SYSTEM
STABILIZER CYLINDER - SIDESHIFT
1. Stroke
2. Completely retracted
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SECTION 35 - HYDRAULIC SYSTEM
STABILIZER CYLINDER DISASSEMBLY - SIDESHIFT
1. Cylinder rod
8. Back-up ring
2. Wiper ring
9. O-ring
3. Seal ring
10. Piston
4. Ring
5. Guide bush
6. Cylinder head
13. Screw
7. Safety screw
WARNING
Cylinder weight: 34.6 kg (76.28 lb).
Lift and place the cylinder on a workbench and
secure it to a vice.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.
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Only if necessary:
- remove the wiper ring (2), the seal rings (3), the
ring (4), the guide bush (5) and the O-ring (9) with
the back-up ring (8) from the cylinder head (7);
- remove the piston guide ring (11) and the piston
seal (10) from the piston (12).
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SECTION 35 - HYDRAULIC SYSTEM
SWING CYLINDER
1. Stroke
2. Completely retracted
WARNING
Always support the structural members so that they
will be stable and safe to work around.
Stop the engine and move the backhoe attachment
control levers through all operating positions to
relieve any residual pressures in the system.
Loosen and remove the nut (1).
Slide out the screw (2) from the opposite side.
Now the pin (3) can come out and release the rod
cylinder.
If necessary hammer to help the pin (3) to come
out.
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Disconnect the feed and return hose to the cylinders and cap all exposed openings.
Loosen and remove the nuts (4) and the screws (5)
(from both sides).
Now it is possible to remove the support (6).
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SECTION 35 - HYDRAULIC SYSTEM
SWING CYLINDER DISASSEMBLY
1. Bushing
2. Wiper ring
11. O-ring
3. Cylinder rod
4. Wiper ring
5. Seal ring
6. Ring
15. Piston
7. Guide bush
8. Bushing
9. Seal ring
WARNING
Cylinder weight: 31 kg (68.34 lb).
Lift and place the cylinder on a workbench and
secure it to a vice.
Be sure that the cylinder is placed horizontally.
Drain hydraulic oil from the cylinder.
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Only if necessary:
- remove the wiper ring (4), the seal ring (5), the
ring (6), the guide bush (7) and the back-up ring
(12) with the O-ring (11) from the king pin (10).
- remove the piston seal (13) and the piston guide
ring (14) from the piston (15).
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SECTION 35 - HYDRAULIC SYSTEM
BACKHOE ATTACHMENT LOCK CYLINDER - SIDESHIFT
4 sideshift locking cylinders are installed on the
backhoe loader.
Their function is to lock the carriage once the backhoe attachment is in digging position.
The cylinder consists of:
1. Body
2. Cylinder
3. Gasket
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SPECIAL TOOLS
PN CNH
DESCRIPTION
380000721
Wrench
380000722
Wrench
380000724
Wrench
APPLICATION
Telescopic dipper cylinder head
Stabilizer cylinder head (sideshift)
Loader bucket cylinder head
Backhoe boom cylinder head
Backhoe dipper cylinder head
Backhoe bucket cylinder head
380000725
Wrench
380000726
Wrench
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SECTION 35 - HYDRAULIC SYSTEM
129
Spool stroke
80 Nm (59 lbfft)
30 Nm (22 lbfft)
50 Nm (37 lbfft)
40 Nm (30 lbfft)
50 Nm (37 lbfft)
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130
4. STABILIZER CONTROLS: the right-hand control is for the right-hand stabilizer and the lefthand control is for the left-hand stabilizer.
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SECTION 35 - HYDRAULIC SYSTEM
COMPONENTS
RIGHT HAND HYDRAULIC CONTROL LEVER
1. Valve
2. Plate
11. Cover
3. Screw
12. Switches
4. Nut
13. Washer
5. Boot
14. Spacer
6. Connector
15. Clip
7. Wedge
16. Clip
8. Half handle
9. Screw
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132
1. Valve
11. Cover
2. Plate
3. Screw
13. Washer
4. Nut
14. Spacer
5. Boot
15. Clip
6. Connector
16. Clip
7. Wedge
8. Half handle
9. Screw
19. Connector
20. Wedge
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SECTION 35 - HYDRAULIC SYSTEM
DISASSEMBLY AND ASSEMBLY
Disassembly
Release the pressure from the hydraulic systems by
carrying out the operations described below.
Turn the starter switch key to ON but do not start
the engine.
Turn pilot control cancellation switch to the ON position.
Move the hydraulic control levers through all positions.
Turn the starter switch key to OFF. Disconnect the
negative battery cables.
Mark the position of the lever parts (see the
exploded view on previous pages).
Remove the knob (P) and the support (S).
Remove the bracket (O) with the relevant screws
(with left hydraulic control lever).
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134
Lift the rubber boot (RL) for left control lever and the
rubber boot (RR) for right control lever.
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SECTION 35 - HYDRAULIC SYSTEM
- Remove the screws (V1) and take out control
lever from the column.
Assembly
Proceed in reverse order.
Follow the marks made during disassembly and tighten
the nut (4) to a torque of 36 44 Nm (26 32 lbfft).
135
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136
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SECTION 35 - HYDRAULIC SYSTEM
HYDRAULIC CONTROL LEVER VALVE OVERHAUL
Disassembly
Mark the direction of installation of all disassembled
parts.
Remove the U/J cam (1) using a key.
Remove the plate (2).
Remove the shim (3) from the upper body (4).
Extract the rod guide (5) and replace the seal rings
(6) and (7).
Drift the rod (8) out.
Remove the spring guide (9), the spring (10) and
the shims (11).
Extract the spool assembly.
Hold the cover (12) and remove the safety ring
(13).
Remove the spring (14) and the spool (15).
Remove and note the thickness of the shims (16).
Proceed in the same manner for the other rods.
Secure the upper body (4) in a vice.
Loosen and remove the screw (17) using a key and
replace the O-ring (18).
Separate the upper (4) and lower (19) bodies and
replace the seal rings (20) and (21).
Assembly
To reassemble, proceed in the reverse order to that
of removal.
In the case of reassembly without changing the U/J
cam (1), put the same value of shims (3) as those
in place.
After changing the U/J cam (1) adjust the pressure
of the cam on the rods.
Install a 2 mm (0.079 in) shim (3), check that the
recessing of the push-rods is less than 0.2 mm
(0.009 in), modify the shimming to more or less if
required.
Assemble the new seal rings (6), (7) and O-rings
(18), (20) and (21).
Lubricate the moving parts.
Apply brake thread fluid on the threads of the U/J
cam (1) and the screw (17).
Tighten the cam (1) and the screw (17) to a tightening torque of 50 Nm (37 lbfft).
137
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138
TROUBLESHOOTING
PRELIMINARY CHECKS
When troubleshooting, the pressure and flow rate
test must be carried out in a systematic manner
and the results analyzed.
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SECTION 35 - HYDRAULIC SYSTEM
139
CAUSE
ACTION
Worn pump
CAUSE
Valve spool leaking.
ACTION
Examine lift section of loader control
valve assembly for wear or scoring.
Examine/reseal piston and gland.
LOADER ATTACHMENT
TROUBLE
The lifting system fails to
operate, is slow or loses
power.
The bucket fails to operate,
is slow or loses power.
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140
BACKHOE
Refer to the following backhoe fault finding chart after first considering the preceding charts. This chart should
only be referred to if the supply system is operating normally, thereby confirming that the hydraulic supply systems and the pump are correctly operating. See also Fault finding hydraulic pump.
TROUBLE
The lifting system is
inoperative, is too slow,
loses power or does not
hold.
CAUSE
ACTION
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SECTION 35 - HYDRAULIC SYSTEM
141
SWING
TROUBLE
Right or left swing is
inoperative, is too slow or
loses power.
CAUSE
ACTION
A system temporarily
lowers when given the
control to lift.
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142
HYDRAULIC PUMP
TROUBLE
Noisy system.
Oil heating.
CAUSE
ACTION
Visual check.
Visual check.
Tank overfilled.
Contaminated oil.
Too high/low setting of the relief valve. Drain the tank and refill with clean oil.
Test relief valves.
Oil in system too light.
Foamy oil.
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580T
580ST
590ST
695ST
SECTION 39 - CHASSIS
DESCRIPTION ................................................................................................................................................. 3
REMOVAL AND INSTALLATION OF COMPONENTS .................................................................................... 5
COMPONENTS WITHIN THE CHASSIS .................................................................................................... 5
COMPONENTS OF THE LOWER PART OF THE CHASSIS ..................................................................... 6
COMPONENTS ATTACHED OUTSIDE THE CHASSIS........................................................................... 10
COMPONENTS OF THE UPPER PART ................................................................................................... 11
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2
SECTION 39 - CHASSIS
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SECTION 39 - CHASSIS
DESCRIPTION
The chassis of the Backhoe Loader is manufactured
as a one-piece unit, on which the main assemblies
are attached, or which supports the main assemblies.
TYPES
Some kinds of chassis are available, which differ
from each other according to some main characteristics of the Backhoe Loader.
Backhoe attachment:
- Center pivot (fixed central rotation) (only 695ST):
the backhoe attachment is directly connected to
the chassis and cannot shift laterally;
- Sideshift: the backhoe attachment is installed on a
sideshift support and can shift laterally on the
chassis guides.
Steering:
- 2 wheel steering (2WS);
- 4 wheel steering (4WS).
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4
2WS SIDESHIFT CHASSIS
SECTION 39 - CHASSIS
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SECTION 39 - CHASSIS
ENGINE
Supported by 2 rubber silent blocks and held in
position by 2 support brackets.
Remove:
WARNING
Since they are fastened to each other, the engine
and the transmission operate as a one-piece unit. If
separated in the machine they are not self supporting and will collapse causing injury or damage to
the machine.
TRANSMISSION
Attached to the rear side of the engine and supported by means of brackets provided with rubber
silent blocks.
To make repairs that require disassembly of the
transmission or engine it will be necessary to
remove the engine/transmission as a complete unit
from the chassis.
To remove the engine/transmission from the
machine, it will be necessary to carry out some
operations.
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6
SECTION 39 - CHASSIS
FRONT AXLE
The front axle is attached to the underside of the
chassis by 6 through screws (2WS) or 4 through
screws (4WS).
To remove front axle from the machine see
REMOVAL FROM MACHINE in SECTION 25 FRONT AXLE.
REAR AXLE
The rear axle is attached to the frame at the rear of
the machine by 4 through screws.
To remove rear axle from the machine see
REMOVAL FROM MACHINE in SECTION 27 REAR AXLE.
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SECTION 39 - CHASSIS
CARDAN SHAFTS
2WS
1. Front axle
2. Front cardan shaft
3. Screw [tightening torque 33 39 Nm (24 29 lbfft)]
4. Bracket
5. Bracket
6. Screw [tightening torque 35 41 Nm (26 30 lbfft)]
7. Rear cardan shaft
8. Rear axle
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8
SECTION 39 - CHASSIS
4WS
1. Front axle
2. Bracket
3. Screw [tightening torque 35 41 Nm (26 30 lbfft)]
4. Front cardan shaft
5. Bracket
6. Screw [tightening torque 35 41 Nm (26 30 lbfft)]
7. Rear cardan shaft
8. Rear axle
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SECTION 39 - CHASSIS
COUNTERWEIGHT
4WS (B):
3. Standard counterweight .............160 kg (352 lb)
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10
SECTION 39 - CHASSIS
TANKS
The hydraulic oil tank (1) and the fuel tank (2) are
attached to the chassis under the cab, respectively
to the right-hand and left-hand side of the machine.
When drained of their contents, both tanks can be
removed from the machine, disconnecting the relevant hoses and removing the fastening screws
[tightening torque of 85 Nm (63 lbfft)].
IMPORTANT: make sure that all inlets and pipes are
plugged or blanked off to prevent the dirt from entering them.
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SECTION 39 - CHASSIS
COMPONENTS OF THE UPPER PART
CAB
A. Front coupler
6. Nut
B. Rear coupler
7. Retaining screw
C. Cab skirts
8. Washer
1. Main frame
9. Cab floor
2. Anti-vibration
3. Dampener
11. Support
4. Washer
12. Bushing
5. Washer
11
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12
SECTION 39 - CHASSIS
Copyright
580T
580ST
590ST
695ST
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2
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SECTION 41 - STEERING SYSTEM
DESCRIPTION
The steering system has the following features:
- double-acting steering cylinder;
- oil tank in common with the main hydraulic system;
- a hydraulic pump located on the rear part of the
transmission;
- steering (or power steering) control valve located
on the steering wheels column.
The oil is taken from the tank and reaches the
pump.
The front pump flow is directed to the loader and
backhoe attachment control valves.
Thanks to the presence of a flow divider, the rear
pump delivery guarantees priority oil delivery to the
steering system.
The flow divider includes a load-sensing valve and a
steering system pressure relief valve.
According to the machine model, the steering system can be of 2 types:
- 2WS steering system;
- 4WS steering system.
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4
1. Flow divider
5. Oil filter
2. Power steering
6. By-pass valve
3. Hydraulic tank
7. Radiator
4. Return manifold
8. Front axle
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SECTION 41 - STEERING SYSTEM
OPERATION
Power steering - Neutral position
Pump pressure
Trapped oil
Stand-by pressure
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6
Pump pressure
Trapped oil
Metered pressure
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SECTION 41 - STEERING SYSTEM
1. Flow divider
6. By-pass valve
2. Power steering
7. Radiator
3. Hydraulic tank
8. Front axle
4. Return manifold
5. Oil filter
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8
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SECTION 41 - STEERING SYSTEM
OPERATION
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10
3b
2a
2b
2WS
2WS
4WS
CRAB
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SECTION 41 - STEERING SYSTEM
POWER STEERING
The power steering consists of a metering and
emergency pump that includes:
- a gearwheel with fixed stator with inner teeth and
a rotor with outer teeth;
- a 4-way rotary control valve consisting of an outer
sleeve and an inner selection rotor;
- a rotor connected to the steering wheel by means
of the steering column, which can be of two types,
fixed or adjustable;
- a cardan shaft which is mechanically tied to the
gearwheel and to the outer sleeve, and allows the
transmissions movement;
- a set of centering springs between the outer
sleeve and the inner rotor.
TECHNICAL SPECIFICATIONS
L. Left control port (steering cylinder)
R. Right control port (steering cylinder)
P. Inlet to steering pump
T. Outlet to oil tank
LS. Outlet to steering pump
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12
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SECTION 41 - STEERING SYSTEM
COMPONENTS
13
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14
A. Anticavitation valve
20. Gasket
21. O-ring
22. Seal
24. Bearing
1. Screw
2. Cover
26. Spring
3. O-ring
27. Spacer
4. Spring
28. Sleeve
5. Plug
29. Plug
6. Ball
30. O-ring
7. Rotor/stator gear
31. Spring
8. Plate
32. Poppet
9. Shaft
33. O-ring
34. O-ring
35. Ball
12. Ball
36. Pin
37. Spacer
14. O-ring
15. Spring
39. Poppet
16. Plug
40. Spring
41. O-ring
18. Spool
42. Plug
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SECTION 41 - STEERING SYSTEM
DISASSEMBLY
Cleanliness is extremely important when repairing
the power steering.
Work in a clean area.
Before disconnecting the lines, thoroughly clean the
area.
Use a wire brush to remove foreign material and
debris.
Use protective material on vice jaws.
Power steering unit distortion can result if jaws are
over-tightened.
M = mark
15
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16
CAUTION
Do not lift the spool-sleeve assembly inside the
power steering unit (10).
Slowly rotate the spool-sleeve assembly to remove
it from the power steering unit.
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SECTION 41 - STEERING SYSTEM
Partially push the spool (18) on the end of the
sleeve, then carefully remove the centering springs
(26) from the spool (18).
The power steering with low input torque uses four
centering springs (26) and two spacers (27).
The standard input torque power steering uses six
centering springs.
M = mark
S1 = low torque springs
S2 = standard springs
NOTE: do not remove any valves other than the
manual check valve and the anti-cavitation valves.
All other valves are factory preset and are non-serviceable.
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18
ASSEMBLY
Check all mating surfaces.
If any parts have scratches or burrs, the power
steering must be replaced.
The use of parts with scratches or burrs can cause
leakage and is therefore not recommended.
Clean all metal parts in clean solvent.
Blow dry with air.
Do not wipe dry with cloth or paper towel because
lint or other matter can get into the hydraulic system
and cause damage.
Do not use grit paper or file or grind these parts.
Lubricate all seals, replace all old seals with new
seals and do not use an excessive quantity of lubricant on the seals of the rotor / stator gear.
Carefully assemble the spool (18) and the sleeve
(28) so that spring slots line up correctly. Rotate
spool while sliding parts together.
M = marks
Test for free rotation.
The spool should rotate smoothly in the sleeve with
finger tip force applied to its end.
Align the spool and the sleeve making reference to
the relevant marks (M).
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SECTION 41 - STEERING SYSTEM
Compress the extended end of the spring set and
push it into the spool (18) - sleeve (28) assembly.
Keep pressure on spring ends while withdrawing
installation tool and pushing forward on springs at
same time.
Central springs set in spring slots. Seat springs
down evenly and flush with upper surface of spool
(28) and sleeve (18).
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20
CAUTION
While inserting the spool-sleeve assembly, make
sure that the parts do not tilt out of position. Gently
push the assembly into place with a slight rotation,
holding the pin so that it does not come out and
gets stuck in the internal groove.
Completely insert the spool-sleeve assembly into
the body.
With aligned spool-sleeve assembly, check for free
rotation by turning the assembly with fingertip force
applied to the end.
Position the power steering unit (10) in a vice.
Lightly clamp on the edges of the mounting area; do
not over-tighten the jaws.
NOTE: make sure that the spool and the sleeve are
flush or slightly below the units surface.
Clean the upper surface of the unit.
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SECTION 41 - STEERING SYSTEM
Rotate the spool and sleeve assembly until the pin
is parallel with the ports face.
Install the shaft (9), making sure it is engaged with
pin (17).
To guarantee proper alignment, mark the shaft (see
reference L2).
When marking the shaft, note the relationship
between slotted end and splined end.
Lubricate and install the O-ring (34).
The lubrication will hold the seal in place.
Note the parallel relationship of reference lines L1,
L2, L3 and L4.
Lubricate and install the O-ring (3).
Remove the cap (2).
Check for proper timing by turning the spool clockwise and feeling pressure in the R port.
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22
NOTES:
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580T
580ST
590ST
695ST
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2
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
TECHNICAL SPECIFICATIONS
GENERAL
ENGINE RADIATOR COOLANT
Anti-freeze - Akcela Premium .................................................................................................12 litres (2.64 gal)
Water ......................................................................................................................................12 litres (2.64 gal)
System type ........................................................... Pressurized FULL FLOW by-pass with expansion chamber
FAN BELT DEFLECTION
Natural suction ........................................................................................................ 13 19 mm (0.51 0.75 in)
Turbocharged.......................................................................................................... 10 16 mm (0.39 0.63 in)
THERMOSTAT
Opening starts at.......................................................................................................................... 82 C (179 F)
Fully open at ................................................................................................................................ 95 C (203 F)
Radiator cap.............................................................................................................................. 0.90 bar (13 psi)
MOUNTING SCREW TORQUE
Coolant/hot water hose connections ...........................................................................................5 Nm (3.7 lbfft)
Air hose connections...................................................................................................................5 Nm (3.7 lbfft)
Heater housing to floor fastening screws .................................................................................6.2 Nm (4.6 lbfft)
COOLANT
Type .................................................................................................................................................... HFC 134a
Coolant quantity ............................................................................................................................ 1.2 kg (2.6 lb)
COMPRESSOR OIL
Type ......................................................................................................... SP20 (PAG type, viscosity index 100)
Oil change amount................................................................................................................. 135 cm3 (8.24 in3)
CHECK CONDITIONS
Air inlet temperature.................................................................................................................. 37.8 C (100 F)
Rated air inlet humidity ................................................................................................................................ 40%
Evaporation temperature ................................................................................................................. 0 C (32 F)
Overheating ..................................................................................................................................... 5 C (41 F)
Inlet air speed ...............................................................................................1.0 - 2.0 - 3.0 m/s (3.3-6.6-9.9 ft/s)
Condensation temperature .............................................................................. 58 C (136 F) (16 absolute bar)
Undercooling .................................................................................................................................... 2 C (35 F)
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4
PERFORMANCE
Performance calculated at 1 m/s (3.28 ft) [191.72 m3/h (6769.31 ft3)]
Exchanged heat ................................................................................................. 5.48 kW
4718.28 kcal/h
0.30 mmH20
(0.012 inH20)
Performance calculated at 2.0 m/s (6.56 ft) [383.4 m3/h (13537.22 ft 3)]
Exchanged heat ................................................................................................. 9.29 kW
7,998.69 kcal/h
0.95 mmH20
(0.037 inH20)
10332.00 kcal/h
1.87 mmH20
(0.074 inH20)
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
CAB HEATING
The cab is heated by a radiator mounted below the
cab seat, which is supplied hot water from the
engine coolant system.
A blower motor mounted behind the cab radiator is
used to transfer the heat into the cab.
CONTROLS
Heater blower control
The three-speed blower is controlled by means of a
knob (1) on the instrument console, to the right of
the operators seat.
Turn clockwise to the first position for slow speed.
A further clockwise rotation selects medium and
fast speeds.
The blower draws outside air from beneath the cab
floor and blows it into the cab through a filter.
Temperature control
The temperature of the air coming from the radiator
is adjusted by rotating the control knob (2), which
opens or closes the radiator valve, thus increasing
or decreasing the water flow as required.
Turn clockwise to increase the temperature of the
air coming from the heater.
By rotating counterclockwise, the temperature is
decreased.
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6
OPERATION
CAB AIR FILTER
Before servicing the air filter situated under the
operators seat, switch off the blower and close all
windows and one door.
Forcibly close the other door.
The resulting back pressure will dislodge loose dirt
from the underside of the filters.
To remove the filter (1), release the retaining straps
(2) and remove the filter element.
Ensure the element, and sealing faces are not damaged on removal.
IMPORTANT: in humid conditions, such as occur
on most early mornings, do not switch on the blower
prior to servicing the filters. Damp particles drawn
into the filter may solidify and prove difficult to
remove without washing.
The filter element is made of specially treated paper
with a sealing strip bonded to the outer face.
Clean this element by blowing with compressed air
from the clean side through to the dirty side. The
compressed air should not exceed 2 bar (29 psi)
and the air line nozzle should be at least 300 mm
(11.8 in) from the element.
HEATER RADIATOR
The heater radiator (1) is fitted in a housing under
the cab seat to guarantee a uniform distribution of
warm or cold air flow.
IMPORTANT: to ensure a good flow of air through
the heater radiator the filter should be cleaned more
frequently when operating in extremely dusty conditions.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
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8
WARNING
Once this operation is complete, reset pin (A) in the
correct start position.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
OVERHAUL
IMPORTANT: when overhauling the heating system
remember that, with the engine running or shortly
after it is turned off, the system will be at engine
temperature and therefore the water will be hot and
under pressure.
To carry out the different checks and operations, it
is necessary to drain the system.
To drain the cooling system, disconnect either hose
at the union tee (1) found behind the engine oil filter,
mounted to the left-hand side of the engine.
RADIATOR CHECK
With the system drained, remove the heater radiator hose connections, the attaching screws and
remove the radiator from the vehicle.
Inspect the radiator (2).
Check that the water flows freely through the heater
line (otherwise, clear any obstruction).
Fins must be free from debris and not damaged:
clean and/or repair.
Clean the heater radiator using compressed air not
exceeding 7 bar (102 psi) taking care not to damage the radiator fins.
Make sure that the radiator is not leaking under
pressure.
Clean the chamber with a damp, cloth and reassemble the housing filter element with the seal
facing the inside of the cover.
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10
HEATING VALVE
To service the control valve (4), disconnect the
hoses and the control tie rod and remove it.
Check its operation and replace it, if worn.
CONTROL PANEL
Check for the correct operation of the control knobs
(5) and (6).
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
11
TROUBLESHOOTING
Items that may cause trouble are listed in the table
below. Anyway, as a general rule, we recommend
carrying out some preliminary checks.
Ensure water flow to the heater radiator is steady
and all air has been removed from the system.
Hoses are unrestricted and not leaking.
Check the electric connections are good and the
blower motor is operational.
The operating cable to the heater valve and valve is
operational.
TROUBLE
Dust enters the cab.
CAUSE
ACTION
Restricted filter.
Defective filter.
Blown fuse.
Replace fuse.
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12
AIR CONDITIONING
PRINCIPLES OF AIR CONDITIONING
The function of the air conditioning system is to
improve the operators comfort by cooling down the
air temperature inside the cab and reducing the
humidity level.
In order to achieve this heat transfer the following
principals of heat generation and transfer are
applied within the air conditioning system.
When two bodies with a different temperature come
together, heat is transferred from one to the other.
On air conditioning systems, an evaporator is used
to maintain the low temperature of the coolant,
which absorbs the heat from the air within the cab.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
13
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14
OPERATING DIAGRAM
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
15
EXPANSION
VALVE
LOW
TEMPERATURE
HIGH PRESSURE
LIQUID FILTERED
AND MOISTURE
REMOVED
LIQUID ATOMIZED
AT A LOWER
TEMPERATURE
RECEIVER DRYER
LOWER
TEMPERATURE
HIGH PRESSURE
LIQUID
EVAPORATOR
CONDENSER
WARM LOW
PRESSURE
VAPOUR
HIGH
TEMPERATURE
HIGH PRESSURE
VAPOUR
COMPRESSOR
HEAT FROM INSIDE
CAB MOVES TO
COOLANT
HEAT MOVES TO
OUTSIDE AIR FROM
COOLANT
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
CONTROLS
CONTROLS (580T)
The air conditioning control can be adjusted to
obtain the desired temperature in the cab.
To activate air conditioning, turn the selector (2).
Upon activation, the lamp (3) turns on. The selector
(1) allows choosing the ideal temperature according
to your requirements.
Positioning selector (1) to 0 and turning selector
(2) you will obtain more or less cold according to the
selector (2) position.
By positioning selector (1) to any other position different from 0, you will obtain instead a mixture of
warm and cold air and the desired climate inside the
cab.
NOTE: the air conditioning can be operated only if
the ventilation selector (4) is not set to the stop position.
Turn the selector (4) for air capacity according to
your requirements.
CONTROLS
(580ST - 590ST - 695ST)
The air conditioning control can be adjusted to
obtain the desired temperature in the cab.
To activate air conditioning, turn the selector (2).
Upon activation, the lamp (4) on the side instrument
cluster turns on. The selector (1) allows choosing
the ideal temperature according to your requirements.
Positioning selector (1) to 0 and turning selector
(2) you will obtain more or less cold according to the
selector (2) position.
By positioning selector (1) to any other position different from 0, you will obtain instead a mixture of
warm and cold air and the desired climate inside the
cab.
NOTE: the air conditioning can be operated only if
the ventilation selector (3) is not set to the stop position.
Turn the selector (3) for air capacity according to
your requirements.
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18
OPERATION
COOLANT
To achieve the absorption and the release of heat
which is, in essence, the function of an air conditioning system, requires the use of a suitable coolant a liquid that has a relatively low temperature
boiling point, plus certain desirable safety and stability features.
The coolant used in the air conditioning system is
coolant HFC 134a.
NOTE: to help protect the environment legislation
has been introduced in most territories banning the
release into the atmosphere of coolants, including
HFC 134a. All service procedures contained in this
manual can be carried out without the need to
release coolant into the atmosphere.
In order to prevent the incorrect type of coolant
being charged to the system the service valves fitted to the Backhoe Loader and necessary to connect up coolant recovery, evacuation and recycling/
re-charging equipment will be of two different sizes
as recognized and specified by the air conditioning
industry.
WARNING
Coolant HFC 134a is not compatible with coolant
R-12. Do not try to replace coolant HFC 134a with
coolant R-12 or to test the system using instruments or tools previously used with R12, as the
system could get damaged.
HFC 134a coolant is stable at all operating temperatures and able to absorb great quantities of heat.
The boiling point of HFC 134a is -22 C (-7.6 F) at
atmospheric pressure.
If the pressure is increased, HFC 134a will readily vaporize to absorb heat at temperatures
between -11.7 C (10.94 F) at 1.9 bar (28 psi)
and 0 C (32 F) at 2.9 bar (42 psi) in the evaporator.
At higher pressures, HFC 134a will condense and
give off heat at temperatures between 48 C
(118.4 F) at 12.4 bar (180 psi) and 58 C
(136.4 F) at 15.85 bar (230 psi) in the condenser.
WARNING
HFC 134a can be dangerous if improperly handled.
Therefore it is important the following warning and
directions are adhered to.
Never expose any part of the air-conditioner system
to flame or excessive heat because of risk of fire or
explosion, and the production of phosgene gas.
Never disconnect or disassemble any part of the airconditioning system as escaping coolant can cause
frostbite.
WARNING
If coolant should contact the skin use the same
treatment as for frostbite.
Warm the area with your hand or lukewarm water
32 C (89.6 F), cover the area loosely with a bandage to protect affected area against infection and
consult a doctor immediately.
If coolant should contact the eyes wash immediately in cold clean water for at least 5 minutes and
consult a doctor immediately.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
COMPRESSOR
The compressor is mounted on the left-hand side of
the engine and is belt driven by the crankshaft pulley.
The compressor separates the low and high pressure sides of the system and has two functions:
- raising the coolant temperature by compressing
to a higher degree of temperature than the ambient (outside air) temperature;
- circulating the required volume of coolant through
the system.
The compressor is a 7-cylinder wobble plate unit,
housed in a die-cast aluminium housing.
The drive to the wobble plate comes from the pulley, through the clutch to the main driveshaft.
Attached to the driveshaft, there is a cam rotor
which oscillates the wobble plate.
The wobble plate is prevented from rotating by a
static gear engaging with teeth formed in the face of
the plate.
The seven pistons are connected to the wobble
plate by rods located in ball sockets.
Coolant is drawn in on the downward stroke of a piston through the reed valves located either end of the
cylinder assembly.
Coolant enters the cylinder assembly through a gallery in the outer circumference of the cylinder
assembly.
During the upward stroke, the piston compresses
the coolant and expels it through another reed valve
into an inner gallery in the cylinder and, from here,
out into the coolant system.
The compressor is lubricated with a Polyalklene
Glycol (PAG) oil Type SP20. This oil can be mixed
with coolant and is carried around in the coolant
system itself.
During the operation of the air conditioning system,
the compressor is activated by a clutch which
engages or disengages it as required.
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TEMPERATURE SENSOR
The air conditioner temperature adjusting sensor is
mounted on the blower motor.
It is a device which turns the compressor clutch on
and off to maintain a constant average evaporator
temperature and senses the evaporator temperature using a thermistor (1).
The sensor compares the voltage of the thermistor,
which depends on the temperature of the evaporator, with the voltage across the potentiometer of the
in-cab temperature control switch.
The switch upon comparing the two voltages determines whether the compressor clutch should be
switched on or off in order to maintain the
desired in cab temperature control.
LOW-PRESSURE CUT-OUT SENSOR
The low-pressure sensor (1) is on the upper part of
the filter, situated in front of the radiator.
The purpose of the sensor is to shut off the compressor in case of low pressure in the cooling system.
Low coolant pressure may occur due to a faulty
expansion valve, icing up of the expansion valve
orifice or coolant loss.
Low coolant pressure may result in damage to the
compressor pump.
The low-pressure sensor is set by the Manufacturer.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
CONDENSER
The condenser (1), located at the front of the
machine in front of the engine radiator consists of a
number of turns of continuous coil mounted in a
series of thin cooling fins to provide a maximum of
heat transfer in a minimum amount of space.
The condenser receives the hot, high pressure
coolant vapour from the compressor.
The hot vapour passes through the condenser coils
and outside air is drawn through the condenser by
the engine cooling fan.
Heat moves from the hot coolant vapour into the
cooler outside air flowing across the condenser
coils and fins.
When the coolant vapour reaches the pressure and
temperature that will induce a change of state, a
large quantity of heat is transferred to the outside
air and the coolant changes to a high pressure
warm liquid.
The warm liquid coolant continues onto the
receiver/drier where it is filtered and desiccated, to
remove any moisture, before passing through an
outlet line to the thermostatic expansion valve.
RECEIVER DRYER
The receiver/dryer (1) stores the liquid coolant to
make sure that a steady flow to the expansion valve
is maintained also under extremely different operating conditions.
The drier contains a desiccant (molecular sieve)
which absorbs any moisture within the system, and
a filter which prevents the entry of foreign particles.
NOTE: any moisture in the air conditioning system
is extremely harmful. Moisture not absorbed by the
dehydrator will circulate with the coolant and droplets may collect and freeze in the thermostatic
expansion valve orifice. This action will block the
coolant flow and stop the cooling action. Moisture
will also react with coolant HFC 134a and the lubricant to form a corrosive acid.
The desiccant can only absorb a limited amount of
moisture before reaching saturation point. Because
of this, after any system component replacement or
repairs requiring entry into the system, the receiver/
dryer should be replaced.
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EXPANSION VALVE
The expansion valve (1) is located underneath the
evaporator in the pressure line coming from the
receiver/dryer and performs the following functions:
- metering action
(a metering orifice changes the liquid coolant from
a high-pressure low-temperature liquid to a lowpressure, lower-temperature atomized liquid);
- modulating action
(a thermostatically controlled valve within the
expansion valve body controls the volume of liquid coolant passing through the orifice and makes
sure that the coolant is fully vaporized within the
evaporator; the liquid coolant could damage the
compressor reed valves or freeze the pistons);
- control action
(the valve responds to changes in the cooling
requirements; when an increased cooling is
required, the valve opens to increase the coolant
flow, and when less cooling is required, the valve
closes and decreases the coolant flow).
Operation
All of the needed temperature sensing and pressure
sensing functions are consolidated into this basic
unit and no external tubes are required for these
purposes.
The coolant from the condenser and receiver dryer
enters the thermostatic expansion valve as a high
pressure warm liquid.
Upon passing through the ball and spring controlled
metering orifice, the pressure and temperature of
the coolant is reduced and the coolant leaves the
thermostatic expansion valve as a low pressure,
lower temperature atomized liquid.
The atomized liquid now passes through the evaporator where it absorbs heat before returning via the
expansion valve to the compressor as a warm low
pressure vapour.
There are two coolant passages in the valve.
One passage is in the coolant line from the condenser to the evaporator and contains the ball and
spring type orifice valve.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
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EVAPORATOR
The evaporator is located beneath the cab seat and
consists of a number of turns of continuous coils
mounted in a series of thin cooling fins to provide a
maximum of heat transfer in a minimum amount of
space.
Low temperature coolant in the evaporator absorbs
heat from the hotter air in the operators compartment, thereby cooling the air.
AIR FILTER
The blower fan draws warm air from outside the cab
through the intake filter (2) below the cab floor and a
ready cooled dehumidified air through the recirculation grille (1).
The air passes over the evaporator then into the
cab through the six louvered diffusers.
Two diffusers are located on the front instrument
panel to direct air onto the windshield.
Two are located at the base of the rear posts to
direct air onto the rear window.
Two additional vents are located at the front and
rear of the seat base to direct air at the operators
feet.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
25
WARNING
Before dismantling an air conditioning system for
repair the gas within the system must be discharged and recovered using a certified recovery
unit designed for the type of coolant gas used in the
system.
NEVER release coolant gas into the atmosphere.
ALWAYS wear safety goggles and gloves when
servicing any part of the air conditioning system.
To prevent the entry of any foreign material, it is
necessary to observe some precautions.
Ensure all tools, gauges, hoses and replacement
parts are kept clean and dry and are suitable for the
type of coolant gas used in the system.
PRELIMINARY CHECKS
Always conduct the preliminary fault finding checks
before performance testing the system.
Run the engine at 1000-1200 rpm for 10 minutes
with the air conditioner set to maximum cooling and
the blower at high speed.
Check that the heater temperature control is
switched OFF.
Check that the blower fan is operating at all
speeds.
Check that the compressor clutch engages when
the temperature control switch is turned from OFF
to ON position. A clicking sound indicates the clutch
is engaging. If the clutch fails to operate it may indicate an electric problem in the high low pressure
cut out switches or malfunction of the electric drive
clutch on the compressor.
Check the engine cooling fan is drawing cool air
through the condenser.
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7. Shut-off valve
3. Shut-off valve
Operating precautions
IMPORTANT: always ensure the shut-off valves
are closed (turn clockwise until seated) during all
test operations.
In the closed position, coolant circulates around the
valve stems to the gauges. Therefore, when the
manifold gauge set is connected into a system,
pressure is registered on both gauges.
- NEVER open the HIGH SIDE shut off valve when
the system is operating.
- ALWAYS open the LOW SIDE shut off valve
when adding coolant.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
27
WARNING
To avoid personal injury, stop the backhoe loader
engine during connection of the manifold gauge set.
Check that the gauge set shut off valves are closed
(turned fully clockwise).
Connect the high side gauge hose (normally red) to
the high pressure (discharge) side service valve
and the low side gauge hose (normally blue) to the
low pressure (suction) side service valve on the
backhoe loader. Ensure the hose connections are
fully tightened.
IMPORTANT: prior to connection of the manifold
gauge set, identify the suction (low pressure) and
discharge (high pressure) service gauge ports. The
high pressure service valve is always in the line
from the compressor to the condenser.
The high and low pressure service valves on the
backhoe loader are spring-loaded valves and will be
automatically opened when the test hose is connected.
NOTE: the test hose must incorporate a valve
depressor to actuate this type of valve.
The service valves have a protective cap. This cap
must be removed for test gauge connections and
replaced when service operations are completed.
Test procedure
Re-check that both the high and low side shut off
valves on the manifold gauge set are fully closed.
Run the engine at 1000 1200 rpm.
Turn the heater temperature control OFF.
Operate the system at maximum cooling, with the
blower fan at high speed for 10 minutes to stabilize
all components.
Check the manifold low pressure gauge reading
is within the specified range of approximately
0.28 2.48 bar (4.06 35.97 psi).
Check the manifold high pressure gauge reading
and compare the reading to the pressure indicated
on the pressure temperature chart below.
Measure and compare the temperature of conditioned
air entering the cab through the louvered air diffusers
with the ambient air at the air intake filters on the outside of the cab.
If the system is operating correctly, the conditioned air
entering the cab should be 6 - 9 C (42.8 - 48.2 F)
cooler than the ambient temperature of the outside
air.
If it is confirmed that the system is not operating
correctly refer to the fault diagnostic charts and performance test gauge reading examples on the following pages for possible corrective action.
WARNING
C (F)
bar (psi)
27 (80.6)
29 (84.2)
32 (89.6)
35 (95)
38 (100.4)
41 (105.8)
43 (109.4)
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TROUBLE
Evaporator air not cold.
CAUSE
Low coolant charge.
ACTION
Perform leak tests and repair.
Drain the system.
Charge system, re-test system.
Expansion valve to
evaporator tube shows
considerable condensation
or frost.
Too cold to touch.
Stuck valve.
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TROUBLE
Evaporator air warm.
ACTION
Inspect for dirty condenser restricting
air flow and cooling.
Check operation of condenser cooling
fans. Repair or replace as needed.
TROUBLE
CAUSE
Insufficient cooling.
ACTION
Discharge the system.
Replace receiver/drier.
Inspect all lines and tubing from
compressor outlet to expansion valve.
Replace if needed.
Drain the system.
Charge the system.
Re-test.
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TROUBLE
CAUSE
ACTION
Discharge the system.
Replace the compressor.
Drain the system.
Charge the system.
Re-test.
TROUBLE
CAUSE
Insufficient cooling.
Low pressure reading does
not fluctuate with changes in
temperature control switch
(pressure should lower until
compressor cycles).
ACTION
Perform leak test.
Discharge the system.
Repair leaks.
Replace receiver/drier.
Check oil level.
Drain the system.
TROUBLE
Compressor cycles ON and
OFF too frequently.
ACTION
Stop engine and shut off air
conditioning.
Replace temperature control switch.
Re-test system and check
compressor cycling.
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4. Not used
Problem
Little or no cooling.
Cause
Coolant slightly low.
Conditions*
Too low pressure on low-pressure side.
The gauge should read 1 2 bar (14.5 29 psi).
Corrective procedures
Leak test the system.
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4. Not used
Problem
Corrective procedures
Insufficient cooling.
Cause
Repair leaks.
Check compressor oil to ensure no loss.
Drain the system.
Charge the system.
Diagnostic
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4. Not used
Problem
Corrective procedures
Insufficient cooling.
Cause
Air in the system.
Conditions*
Low side pressure reading does not change when
compressor cycles ON and OFF.
High side pressure slightly high or slightly low. The
gauge should read 13.3 14.8 bar ((193 215
psi)).
Evaporator air not cold.
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4. Not used
Problem
Corrective procedures
Insufficient cooling.
Cause
Diagnostic
Compressor malfunction.
Conditions*
Low side pressure too high. The gauge should read
1 2 bar (14.5 29 psi).
Too low pressure on high-pressure side. The gauge
should read 13.3 14.8 bar ((193 215 psi)).
Evaporator air not cold.
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4. Not used
Problem
Little or no cooling. Engine overheats in some
cases.
Cause
Condenser not functioning properly.
Conditions*
Low side pressure too high. The gauge should read
1 2 bar (14.5 29 psi).
High side pressure too high. The gauge should
read 13.3 14.8 bar (193 215 psi).
Liquid line hot.
Evaporator air warm.
High pressure switch cutting out.
Corrective procedures
Check belt. Loose or worn drive belts could cause
excessive pressures in the compressor head.
Look for clogged passages between the condenser
fins and coil, or other obstructions that could reduce
condenser airflow.
If engine is overheating replace engine thermostat
and radiator pressure cap.
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4. Not used
Problem
Corrective procedures
Little or no cooling.
Cause
Large amount of air in system.
Conditions*
Low side pressure too high. The gauge should read
1 2 bar (14.5 29 psi).
Too low pressure on high-pressure side. The gauge
should read 13.3 14.8 bar (193 215 psi).
Evaporator air not cold.
Replace receiver/drier.
Drain the system.
Charge the system.
Performance test the system.
Diagnostic
Air in the system. Air and humidity contained in it
contaminate the system: therefore, it will operate
incorrectly.
NOTE: * test procedure based upon ambient temperature of 35 C (95 F).
For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature
chart.
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4. Not used
Problem
Little or no cooling.
Cause
Conditions*
Low side pressure too high. The gauge should read
1 2 bar (14.5 29 psi).
High side pressure too high. The gauge should
read 13.3 14.8 bar (193 215 psi).
Evaporator air warm.
Evaporator and suction hose (to compressor) surfaces show considerable moisture.
Corrective procedures
Check for sticking expansion valve as follows:
- operate the system at maximum cooling;
- check the low-pressure side gauge. The pressure
should lower slowly.
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4. Not used
Problem
Insufficient cooling.
Cause
Improper operation of thermostatic expansion valve
(stuck open).
Conditions*
If the previous procedure indicates that the expansion valve is defective, proceed as follows:
- discharge the system;
- replace the expansion valve;
High side low. The gauge should read 13.3 14.8 bar
((193 215 psi)).
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4. Not used
Problem
Little or no cooling.
Cause
Restriction in high side of system.
Conditions*
Too low pressure on low-pressure side. The gauge
should read 1 2 bar (14.5 29 psi).
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4. Not used
Problem
Corrective procedures
Cause
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2. Recovery/recharging unit
ting and the blue (low side) hose to the low side
(suction) fitting.
The following is a summary of the steps for discharging the system using a recovery/recycling
unit.
WARNING
Never discharge coolant gas into the atmosphere.
Always wear safety goggles and gloves when working with coolant. Only use authorized coolant tanks.
IMPORTANT: always follow the manufactures
instructions when operating recovery equipment.
Run the vehicles air conditioning system for a few
minutes.
Set up the recovery unit following manufacturers
instructions. Ensure that the units red (high side)
hose is connected to the high side (discharge) fit-
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System
Vacuum
Temperature
In mercury
Cm (in) of
mercury
C (F)
28.0
71.0 (28.9)
38 (100.4)
28.9
73.4 (29.0)
27 (80.6)
29.4
74.6 (29.4)
16 (60.8)
29.7
75.4 (29.7)
5 (41)
29.8
75.7 (29.8)
-7 (19.4)
29.9
75.9 (29.9)
-18 (-0.4)
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2. Recovery/recharging unit
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
OVERHAUL
WARNING
Before disconnecting components in the air conditioning system the coolant gas must be discharged
and recovered using a certified recovery system.
Refer to Discharging the system. Do Not discharge
the gas into the atmosphere.
If an air conditioning component is to be replaced
during a system overhaul it is necessary to drain
any coolant oil that has collected in the component
being replaced into a clean calibrated container.
A volume of clean coolant oil equivalent to that
removed from the replaced component must then
be added to the new item before being installed onto
the backhoe loader.
Upon completion of the repair evacuate, recharge,
leak test and performance test the system to ensure
correct operation.
EXPANSION VALVE
The expansion valve is not a serviceable item and
must be replaced if defective.
Fully discharge the air conditioning system.
Remove the seat to gain access to the valve.
To gain access to the expansion valve partially lift
the evaporator core from its position in the cab floor.
Remove the screw securing the inlet and outlet connections to the valve and pull valve from tubing.
Replace the O-ring seals and lubricate with coolant
oil prior to installing the valve using disassembly
procedure in reverse.
Evacuate, leak test and recharge the system.
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EVAPORATOR
Discharge and recover coolant gas using certified
recovery systems.
Remove the seat and cover plate to reveal evaporator assembly (1).
Remove temperature cycling control thermocouple.
Disconnect tubing to expansion valve.
Remove evaporator.
Check the evaporator assembly fins for damage.
Straighten fins if necessary.
Clean the evaporator core of all foreign material to
be sure it is free of obstructions.
Check the evaporator assembly for indications of
coolant leakage. If damage or leaks are evident,
replace the evaporator core.
If a new evaporator is to be installed drain the coolant oil in the evaporator into a clean calibrated container.
Measure the quantity of oil obtained and add the
same quantity of new coolant oil directly into the
replacement evaporator core.
Install evaporator using disassembly procedure in
reverse.
Evacuate, leak test and recharge the system.
ADJUSTING SENSOR OF AIR CONDITIONER
TEMPERATURE
Remove the seat mounting plate.
The temperature adjusting sensor (2) is mounted to
the side of the blower motor assembly.
Carefully pull and disconnect the switch wiring at the
connector.
Remove temperature control switch and replace as
required.
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CONDENSER
Loosen and remove the fixing screws (2).
Remove the front grill (1).
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
AIR FILTER
Before servicing the filter (1), switch off the blower
and close all windows and one door.
Slam the final door closed and the resulting back
pressure will dislodge most of the loose dirt from the
underside of the filter.
Remove the filter (1) and clean it by blowing with
compressed air not exceeding 2 bar (29 psi).
IMPORTANT: make sure you protect your face
before using compressed air.
Blow the dust from the upper surface through the
element to the lower surface. Hold the nozzle at
least 300 mm (11.8 in) from the element to prevent
damage to the paper pleats.
Clean both filter chambers with a damp, lint free
cloth.
Replace the filter element with the rubber seal
uppermost and re-install the covers.
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COMPRESSOR
TECHNICAL SPECIFICATIONS
Basic compressor specifications
Displacement ......................................................................................................................... 155 cm3 (9.46 in3)
Weight ............................................................................................................................................ 9.9 kg (22 lb)
Oil type ....................................................................................................................................................... SP20
Rotation .............................................................................................................................. CW (Clockwise only)
Compressor clutch and pulley air gap ............................................................... 0.9 0.8 mm (0.035 0.031 in)
Belt tension
Measure at the widest gap ...... 10 mm (0.40 in) deflection with 1 kg (2.2 lb) force applied midway between the pulleys
Speed rating
Constant............................................................................................................................................... 6000 rpm
Downshift ............................................................................................................................................. 8000 rpm
Tightening torque
M8 armature retaining nut .....................................................................................17.7 2.9 Nm (13 2.1 lbfft)
M6 cylinder head screws.......................................................................................13.7 2.9 Nm (10 2.1 lbfft)
M8 cylinder head screws....................................................................................34.3 4.9 Nm (25.3 3.6 lbfft)
Clutch dust cover screw ...............................................................................................9 2 Nm (6.6 1.5 lbfft)
Oil filler plug .......................................................................................................19.6 4.9 Nm (14.5 3.6 lbfft)
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
REMOVAL
Discharge the air conditioning system. Disconnect
the wiring harness of the compressor (12) from the
wiring harness of the engine.
Disconnect tubing to compressor.
Remove the washer (7) and the screw (1).
Remove the protective guard (13). Remove the
screw (11).
Remove the nut (14) and the screw (9).
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Remove the washers (5), the nut (6), the screw (2)
and the block (8).
Remove the screw (1), the washers (3) and the belt
tensioner (4).
Remove the screw (10), the washers (2) and the
compressor (12).
INSTALLATION
To install, follow the removal procedure in reverse
order.
Torque the fastening screws to 40 51 Nm
(29 38 lbfft).
NOTE: it is recommended that a new receiver/drier
assembly is installed after any system component
replacement or any repair that requires entry into
the system.
Drain the oil from the new compressor to be fitted
into a clean container, or if the old compressor is to
be refitted, obtain a new can of coolant oil.
Calculate the amount of oil to be installed and refill
the compressor.
Reconnect the hoses to the compressor and tighten
all screws and hoses.
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BELT ADJUSTMENT
The compressor drive belt (1) can be tensioned by
rotating the idler arm (2).
Slacken the idler arm screw and adjust the arm to a
belt deflection of 16 mm (0.63 in).
Once adjusted re-torque the tension arm screw to
33.9 Nm (25 lbfft).
OVERHAUL
Before any internal repair is done, drain the oil from
the compressor:
Remove the oil plug and drain as much oil as possible into a suitable container.
Remove the caps (if present) from suction and discharge ports.
Drain oil from the section and discharge ports into
suitable container while turning the shaft clockwise
only with a socket wrench on the armature retaining
nut.
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1. Screw
6. Cover
2. Dust cover
7. Snap ring
3. Nut
8. Rotor
4. Plate
9. Snap ring
5. Shims
10. Coil
Disassembly
All clutch servicing should be done with the compressor removed from the vehicle. Support the
compressor. If using a vice, do not hold on to the
housing.
If a dust cover (2) is present, remove the 3 or 6
screws (1) holding it in place and remove the cover.
If auxiliary sheet metal pulley is present, remove the
screws holding it in place.
Then remove pulley.
Attach the tool to the cover in front of the clutch disc
and remove the nut (3) using a wrench.
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Assembly
Install the coil (10), making sure that the wire is
located behind the clip on the outside of the body
and that the snap ring (9) is located in the groove.
Position the rotor (8) on the housing hub and carefully slide the rotor (8) down the shaft.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
COMPRESSOR
1. Shaft key
6. Gasket
2. Ring
7. Plate
3. Snap ring
8. Head gasket
4. Gasket
9. Cylinder head
5. Plug
10. Screw
Disassembly
Remove the armature plate, as detailed in the steps
of clutch disassembly.
Remove the shaft key (1) and the ring (2) to expose
the snap ring (3).
Remove the snap ring (3).
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Assembly
Thoroughly clean the seal cavity in the hub.
Use lint free cloth only.
Ensure the new shaft seal O-ring is installed onto
the seal assembly.
Dip the new seal assembly in clean coolant oil and
attach to the seal remover/installer tool.
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SECTION 50 - CAB HEATING AND AIR CONDITIONING
Position the shims over the shaft and refit the shaft
key.
Reinstall the plate as described in clutch reassembly.
CYLINDER HEAD
Disassembly
Drain the coolant oil from the compressor into a
clean graduated container.
Measure and record the quantity of oil obtained.
This information is required during installation of the
new or overhauled unit.
Remove the six cylinder head screws (10) and
using a hide mallet, gently tap the cylinder head (9)
free.
The use of a gasket scraper may also be required
to free the cylinder head from the compressor body.
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Gently pry the plate (7) free from the cylinder block
and remove the gasket (6).
Inspect the plate (7) for damage.
Assembly
Coat the top of the valve plate with clean coolant oil
and reassemble the cylinder head following the
removal procedure in reverse order.
When installing the gaskets and valve plate ensure
they are correctly positioned over the locating pins
in the cylinder block.
Install the cylinder head screws and tighten using
the sequence shown.
Torque initially to 20 Nm (15 lbfft).
When the overhaul is complete add to the compressor a volume of oil equivalent to that drained prior to
disassembly, or as the reclaim measured fill.
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TROUBLESHOOTING
TROUBLE
Unusually high suction
pressure with unusually low
discharge pressure.
CAUSE
Valve plate test.
ACTION
Replace or repair:
Broken head or block gasket.
Broken or deformed reed valve.
Foreign substance under reed valve
or gasket.
Replace or repair:
Shaft seal leak.
Intermittent or inoperative.
Replace.
Replace or repair:
Broken lead wire.
Internal clutch coil defect.
System ground (see system
manual).
Difficult start.
Clutch engaged.
Replace or repair.
Replace or repair.
Replace or repair:
Broken discharge valve reed or
retainer.
Broken suction valve reed.
Broken gasket.
Chattering disengaged
clutch.
Replace or repair:
Adjust air gap.
Defective clutch pulley or front plate.
Copyright
66
NOTES:
Copyright
580T
580ST
590ST
695ST
Copyright
2
Copyright
SECTION 55 - ELECTRIC SYSTEM
ELECTRIC DIAGRAMS
ELECTRIC DIAGRAMS - POWERSHUTTLE ROPS (580T mechanical engine)
FUSES AND RELAYS
Fuse
no.
Rating
Function
F1B
7.5 A
F1C
10 A
F2A
15 A
F2C
15 A
Pilot control
F3A
3A
F3B
3A
F3C
10 A
F4A
5A
F4B
10 A
Backhoe hammer button, sensor + bucket level solenoid valve, transmission disconnect button and differential lock
button
F4C
10 A
Backhoe attachment lock, backhoe attachment travel lock, rear work light
switch
F5A
15 A
F5B
10 A
Low beams
F5C
15 A
Main beams
F6A
7.5 A
Rotating beacon
F6B
7.5 A
F6C
7.5 A
F1A
F2B
K5
K6
K7
K8
K9
F7A
F7B
F7C
F8A
15 A
F8B
15 A
F8C
15 A
K1
K2
Horn relay
K3
Starting relay
K4
Copyright
4
COMPONENTS
NAME
DESCRIPTION
NAME
DESCRIPTION
A2
G1
Battery
A14
Antitheft unit
G67
Alternator
B4
H2
Horn
B5
H4
B26
Bucket sensor
H5
B30
H6
B56
H26
B68
B69
HA3
Optional buzzer
B70
H420
Reverse buzzer
B73
K209
B411
Speed sensor
K211
Starting relay
E2
K224
E3
K226
4WD relay
E38
K605
E40
M1
Starter motor
E44
M17
E45
M64
E46
P2
E47
P125
Speedometer (optional)
E50
S0
E51
S2
4WD switch
E53
Rotating beacon
S3
E54
Rotating beacon
S5
E407
S7
E409
S15
F1
S19
Gearshift lever
F2
S32
F3
S33
S36
F4
S41
F208
S42
Warning switch
F500
General fuse
S54
Horn button
Copyright
SECTION 55 - ELECTRIC SYSTEM
NAME
DESCRIPTION
CONNECTORS
S100
NAME
S101
X1
S126
Lights switch
X2
S135
X3
S127
X4
S141
X6
S210
X7
S404
X8
X10
X13
X14
Y3
Y6
Y7
Y8
Y12
Y34
Y35
Y74
Y105
Y106
Y202
Y203
Y206
Y207
Y209
DESCRIPTION
X19
X21
X22
X24
X26
X27
X28
X29
X31
X34
X35
X36
X38
X40
X44
Copyright
6
NAME
DESCRIPTION
X45
X46
X47
X50
X51
X53
X54
X64
X67
X68
X69
NAME
DESCRIPTION
X205
X206
X207
X208
X209
X210
X411
X420
X421
X600
X603
X72
XC2
X73
XC3
XC4
X82
XC5
X83
XC6
X87
X01
X102
Diode connector
XX
Diode connector
X103
Diode connector
X104
Diode connector
X105
X106
X125
X140
Diode connector
X202
X203
X204
Copyright
SECTION 55 - ELECTRIC SYSTEM
ENGINE LINE DIAGRAM
Copyright
8
Copyright
SECTION 55 - ELECTRIC SYSTEM
Copyright
10
LIGHT LINE DIAGRAM
Copyright
SECTION 55 - ELECTRIC SYSTEM
REAR LIGHT LINE DIAGRAM
11
Copyright
12
WORK LIGHT LINE DIAGRAM
Copyright
SECTION 55 - ELECTRIC SYSTEM
ROTATING BEACON LINE DIAGRAM
13
Copyright
14
Copyright
SECTION 55 - ELECTRIC SYSTEM
COLD START DIAGRAM
15
Copyright
16
INSTRUMENT
Speedometer
Level fuel
Transmission
temperature
Coolant
temperature
Battery charge
INPUT
READING
TOLERANCE
INPUT
TOLERANCE
CALIBRATION
DIRECTION
0 Hz
0 rpm
3 rpm
N/A
Descending
307 Hz
1000 rpm
N/A
60 rpm
Ascending
736 Hz
2400 rpm
N/A
60 rpm
Ascending
240 Ohm
Empty
+0/-6 Ohm
230-240 Ohm
Descending
102 Ohm
1/2 Tank
3 Ohm
98 108 Ohm
Descending
33 Ohm
Full
+4/-2 Ohm
33 42 Ohm
Ascending
900 Ohm
Point B
+0/-6 C (32/21.2 F)
N/A
Descending
114 Ohm
106 C (223 F)
(Red/green line)
5 C (41 F)
Ascending
700 Ohm
Point A
+0/-5 C (32/23 F)
N/A
Descending
95 Ohm
106 C (223 F)
(Red/green line)
93 97 Ohm
Ascending
11 V
10.7 11.3 V
Descending
15.9 V
15.0 15.6 V
Ascending
Copyright
SECTION 55 - ELECTRIC SYSTEM
PIN
NAME
17
FUNCTION
Ignition
10 V 16 V INPUT
Parking brake
Alternator/battery
Alternator D+ input
Not used
Not used
Neutral
Seat switch
10
11
Not used
12
Driving lights
13
Not used
14
Not used
15
Engine pre-heat
16
Not used
17
Not used
18
Not used
19
Speedometer
20
Level fuel
21
Water temperature
22
Transmission temperature
23
Not used
24
Driving lights
25
Not used
26
Not used
27
Not used
28
Not used
29
Not used
30
Not used
31
32
Not used
33
Not used
34
Not used
35
Horn
36
Grounding
Alternator w input
Grounding
Copyright
18
Rating
Function
F1A
15 A
F1B
7.5 A
F1C
10 A
F2A
15 A
F2B
15 A
Air conditioning
F2C
15 A
Pilot control
F3A
3A
F3B
3A
F3C
10 A
F4A
5A
F4B
10 A
Backhoe hammer button, sensor + bucket level solenoid valve, transmission disconnect button and differential lock
button
F4C
10 A
Backhoe attachment lock, backhoe attachment travel lock, rear work light
switch
F5A
15 A
F5B
10 A
Low beams
F5C
15 A
Main beams
F6A
7.5 A
Rotating beacon
F6B
7.5 A
F6C
7.5 A
F7A
10 A
F7B
10 A
F7C
6A
F8A
15 A
F8B
15 A
F8C
15 A
K1
K2
Horn relay
K3
Starting relay
K4
K5
K6
K7
K8
K9
K10
K11
K12
Copyright
SECTION 55 - ELECTRIC SYSTEM
19
COMPONENTS
NAME
DESCRIPTION
NAME
DESCRIPTION
F4
F208
F500
General fuse
G1
Battery
G67
Alternator
H2
Horn
H4
H5
H6
H18
Roof lamp
H26
Speed sensor
HA3
Optional buzzer
BS1
H420
Reverse buzzer
BS2
K209
E2
K211
Starting relay
E3
K224
E38
K226
4WD relay
E40
K230
E44
K605
E45
M1
Starter motor
E46
M17
E47
M39
E50
M41
E51
M49
E55
M56
E406
Rotating beacon
M57
E407
M64
E409
P2
E412
Rotating beacon
P125
Speedometer (optional)
F1
S0
F2
S2
4WD switch
F3
S3
A2
A14
Antitheft unit
B4
B5
B26
Bucket sensor
B30
B53
Radio (optional)
B65
B68
B69
B70
B73
B411
Copyright
20
NAME
DESCRIPTION
NAME
DESCRIPTION
S5
Y74
S15
Y105
S19
Gearshift lever
Y106
S32
Y202
S33
Y203
S34
S35
Y206
S36
Y207
S41
Y209
S42
Warning switch
S100
S101
S126
Lights switch
S135
S137
S138
S140
S141
S210
S404
CONNECTORS
NAME
X1
X2
X3
X4
X6
X7
X8
X10
X12
X13
X14
X55
Current intake
Y3
Y6
Y7
Y8
Y12
Y34
Y35
DESCRIPTION
X19
X21
X22
Copyright
SECTION 55 - ELECTRIC SYSTEM
NAME
DESCRIPTION
X24
X26
X27
X28
X29
X31
X34
X35
X36
X38
X39
X40
X44
X45
X46
NAME
21
DESCRIPTION
X69
X72
X73
X82
X83
X87
X88
X102
Diode connector
X103
Diode connector
X104
Diode connector
X105
X106
X110
X111
X125
X47
X140
Diode connector
X49
X202
X50
X203
X204
X205
X206
X207
X208
X209
X210
X406
X411
X412
X51
X53
X54
X55
X56
X57
X64
X67
X68
Copyright
22
NAME
DESCRIPTION
X420
X421
X600
X603
XC2
XC3
XC4
XC5
XC6
X01
XX
Diode connector
Copyright
SECTION 55 - ELECTRIC SYSTEM
ENGINE LINE DIAGRAM
23
Copyright
24
Copyright
SECTION 55 - ELECTRIC SYSTEM
25
Copyright
26
LIGHT LINE DIAGRAM
Copyright
SECTION 55 - ELECTRIC SYSTEM
REAR LIGHT LINE DIAGRAM
27
Copyright
28
WORK LIGHT LINE DIAGRAM
Copyright
SECTION 55 - ELECTRIC SYSTEM
WINDSHIELD WIPER - WASHER LINE DIAGRAM
29
Copyright
30
CAB LINE DIAGRAM
Copyright
SECTION 55 - ELECTRIC SYSTEM
AIR CONDITIONER DIAGRAM
Evaporator box
S45
11-way connector
Potentiometer
Fuse 25 A
10
Speed switch
Blower motor
11
Temperature switch
12
12 V light
Electric cock
X111
9-way connector
X110
31
Copyright
32
Copyright
SECTION 55 - ELECTRIC SYSTEM
COLD START LINE DIAGRAM
33
Copyright
34
INSTRUMENT
Speedometer
Level fuel
Transmission
temperature
Coolant
temperature
Battery charge
INPUT
READING
TOLERANCE
INPUT
TOLERANCE
CALIBRATION
DIRECTION
0 Hz
0 rpm
3 rpm
N/A
Descending
307 Hz
1000 rpm
N/A
60 rpm
Ascending
736 Hz
2400 rpm
N/A
60 rpm
Ascending
240 Ohm
Empty
+0/-6 Ohm
230-240 Ohm
Descending
102 Ohm
1/2 Tank
3 Ohm
98 108 Ohm
Descending
33 Ohm
Full
+4/-2 Ohm
33 42 Ohm
Ascending
900 Ohm
Point B
+0/-6 C (32/21.2
F)
N/A
Descending
114 Ohm
106 C (223 F)
(Red/green line)
5 C (41 F)
Ascending
700 Ohm
Point A
+0/-5 C (32/23 F)
N/A
Descending
95 Ohm
106 C (223 F)
(Red/green line)
93 97 Ohm
Ascending
11 V
10.7 11.3 V
Descending
15.9 V
15.0 15.6 V
Ascending
Copyright
SECTION 55 - ELECTRIC SYSTEM
PIN
NAME
35
FUNCTION
Ignition
10 V 16 V INPUT
Parking brake
Alternator/battery
Alternator D+ input
Not used
Not used
Neutral
Seat switch
10
11
Not used
12
Driving lights
13
Not used
14
Not used
15
Engine pre-heat
16
Not used
17
Direction
18
Not used
19
Speedometer
20
Level fuel
21
Water temperature
22
Transmission temperature
23
Not used
24
Driving lights
25
Not used
26
Not used
27
Not used
28
Not used
29
Not used
30
Not used
31
32
Not used
33
Not used
34
Not used
35
Horn
36
Grounding
Alternator w input
Grounding
Copyright
36
Rating
Function
F1A
15 A
F1B
7.5 A
F1C
10 A
F2A
15 A
F2B
15 A
Air conditioning
F2C
15 A
Pilot control
F3A
3A
F3B
3A
F3C
10 A
F4A
5A
F4B
10 A
Backhoe hammer button, sensor + bucket level solenoid valve, transmission disconnect button and differential lock
button
F4C
10 A
Backhoe attachment lock, backhoe attachment travel lock, rear work light
switch
F5A
15 A
F5B
10 A
Low beams
F5C
15 A
Main beams
F6A
7.5 A
Rotating beacon
F6B
7.5 A
F6C
7.5 A
F7A
10 A
F7B
10 A
F7C
6A
F8A
15 A
F8B
15 A
F8C
15 A
K1
K3
Starting relay
K4
K5
K6
K7
K8
K9
K10
K11
K12
Copyright
SECTION 55 - ELECTRIC SYSTEM
37
COMPONENTS
NAME
DESCRIPTION
NAME
DESCRIPTION
F1
F2
F3
F4
F5
F112
F113
F500
General fuse
F602
G1
Battery
G67
Alternator
H2
Horn
H7
Reverse buzzer
H26
H606
Buzzer
E3
K102
Starting relay
E18
Roof lamp
K103
Starting
E27
K104
E28
K105
E29
K224
E38
K226
4WD relay
E40
K230
E44
K605
E45
M1
Starter motor
E46
M39
E47
M41
E50
M49
E51
M56
E55
Cigarette lighter
M57
E406
Rotating beacon
M64
E407
P1
E409
P125
Speedometer (optional)
E412
Rotating beacon
A14
Antitheft unit
A53
Radio (optional)
A106
B4
B5
B25
Foot accelerator
B26
Bucket sensor
B30
B66
B69
B107
B411
Speed sensor
B608
Hand accelerator
BS1
BS2
E2
Copyright
38
NAME
DESCRIPTION
NAME
DESCRIPTION
R2
X72
S2
4WD switch
X201
Accelerator knob
S3
Y6
S5
Y8
4WD solenoid
S9
Lights switch
Y12
S15
Y34
Y35
S32
Y74
S33
Y105
S34
Y106
S35
Y200
S36
Y202
S41
Y203
S42
Warning switch
S100
Y206
S101
Y207
S132
Gearshift lever
Y209
S135
S136
S137
S138
S139
S140
S141
S144
S210
SB1
ST3
X17
Seat (optional)
X21
Diagnostic socket
X55
Auxiliary 12 V socket
CONNECTORS
NAME
DESCRIPTION
X1
X2
X3
X4
X6
X7
X8
X10
X12
Copyright
SECTION 55 - ELECTRIC SYSTEM
NAME
DESCRIPTION
X13
X14
NAME
39
DESCRIPTION
X51
X53
X54
X55
X56
X57
X64
X17
X19
X22
X24
X67
X25
X69
X26
X27
X72
X28
X87
X29
X88
X31
X34
X102
Diode connector
X103
Diode connector
X35
X104
Diode connector
X36
X105
X38
X106
X39
X106
X40
X107
X41
X110
X43
X111
X44
X125
X45
X140
Diode connector
X200
X46
X47
X49
X50
X203
X204
Copyright
40
NAME
DESCRIPTION
X205
X206
X207
X208
X209
X210
X220
X401
X406
X411
X412
X420
X421
X603
Buzzer connector
X607
X608
XC1
XC2
XC3
XC4
XC5
XC6
X01
XX
Diode connector
Copyright
SECTION 55 - ELECTRIC SYSTEM
ENGINE LINE DIAGRAM
41
Copyright
42
Copyright
SECTION 55 - ELECTRIC SYSTEM
43
Copyright
44
LIGHT LINE DIAGRAM
Copyright
SECTION 55 - ELECTRIC SYSTEM
REAR WORK LIGHT LINE DIAGRAM
45
Copyright
46
WORK LIGHT LINE DIAGRAM
Copyright
SECTION 55 - ELECTRIC SYSTEM
WINDSHIELD WIPER AND WASHER LINE DIAGRAM
47
Copyright
48
CAB LINE DIAGRAM
Copyright
SECTION 55 - ELECTRIC SYSTEM
AIR CONDITIONING LINE DIAGRAM
Evaporator box
S45
11-way connector
Potentiometer
Fuse 25 A
10
Speed switch
Blower motor
11
Temperature switch
12
12 V light
Electric cock
X111
9-way connector
X110
49
Copyright
50
Copyright
SECTION 55 - ELECTRIC SYSTEM
COLD START LINE DIAGRAM
51
Copyright
52
INSTRUMENT
Level fuel
Coolant temperature
Battery charge
Transmission
temperature
INPUT
READING
TOLERANCE
320 Ohm
+0/-2 Ohm
185 Ohm
3 Ohm (Ref)
6.5 Ohm
+4/-0 Ohm
193 Ohm
ON
5 Ohm
185 Ohm
OFF
5 Ohm
Can message
0 - 3000 rpm
50 rpm
Can message
3 C ( 37.4 F)
Can message
2 C ( 35.6 F)
Can message
3 C ( 37.4 F)
11 V
16 V
385 Ohm
3 C ( 37.4 F)
149 Ohm
2 C ( 35.6 F)
112 Ohm
3 C ( 37.4 F)
Copyright
SECTION 55 - ELECTRIC SYSTEM
CN1
PIN
FUNCTION
53
CN2
NOTE
Not used
Key on power
Wake up
In gear input
Digital input
Driving lights
Digital input
Digital input
Digital input
Not used
Not used
Not used
10
Air conditioning
pressure
Digital input
11
Digital input
12
Menu confirmation
switch input
Digital input
13
UP switch input
14
PIN
FUNCTION
NOTE
Not used
Not used
Buzzer
Not used
Not used
10
Not used
11
Not used
Digital input
12
Not used
Digital input
13
Resistance
15
Cranking
Digital input
14
Thermistor
16
Digital input
Transmission
temperature
17
Not used
15
Not used
18
Parking brake
16
Foot accelerator
0.5 4.5 V
19
Not used
17
Accelerator knob
0.5 4.5 V
20
Minimum
confirmation switch
Digital input
18
Foot accelerator
Output monitored
for diagnostics
21
Decelerator button
Digital input
19
Accelerator knob
Output monitored
for diagnostics
22
Not used
20
Foot accelerator
23
Not used
21
Accelerator knob
24
Not used
22
Not used
25
Transmission oil
pressure
23
Not used
26
Not used
24
Alternator excitation
25
Not used
26
Ground
Digital input
Digital input
Need to fuse at 1
ampere without
disconnect
Digital input
Copyright
54
Rating
Circuit
K3
Starting relay
F1A
15 A
K4
F1B
7.5 A
K5
K6
F1C
10 A
K7
K8
15 A
F2A
K9
K10
Optional
F2B
15 A
Air conditioning
K11
F2C
15 A
Pilot control
F3A
3A
F3B
3A
F3C
10 A
F4A
7.5 A
F4B
10 A
Backhoe hammer button, bucket level solenoid valve + sensor, transmission disconnect button
F4C
10 A
Backhoe attachment lock, backhoe attachment travel lock, rear work light
switches
F5A
15 A
F5B
10 A
Low beams
F5C
15 A
Main beams
F6A
15 A
Rotating beacon
F6B
7.5 A
F6C
7.5 A
F7A
10 A
F7B
10 A
F7C
6A
F8A
15 A
F8B
15 A
F8C
15 A
Copyright
SECTION 55 - ELECTRIC SYSTEM
55
COMPONENTS
NAME
DESCRIPTION
NAME
DESCRIPTION
E407
E409
E412
Rotating beacon
F1
F2
F3
F4
F5
F112
F113
F500
General fuse
F602
G1
Battery
G67
Alternator
H2
Horn
H7
Reverse buzzer
H26
H606
Buzzer
E3
K14
E18
Roof lamp
K102
E27
K103
Starting
E28
K104
E29
K105
E38
K227
4WD relay
E40
K230
E44
K605
E45
M1
Starter motor
E46
M39
E47
M41
E50
M49
E51
M56
E55
Cigarette lighter
M57
E406
Rotating beacon
A14
Antitheft unit
A53
Radio (optional)
A106
A401
B4
B5
B25
Foot accelerator
B26
Bucket sensor
B30
B66
B69
B107
B108
B109
Pressure switch
B112
Speed sensor
B608
Hand accelerator
BS1
Left speaker
BS2
Right speaker
E2
Copyright
56
NAME
DESCRIPTION
NAME
DESCRIPTION
M64
ST3
P125
Speedometer (optional)
X17
Seat (optional)
R2
X55
Diagnostic socket
S2
4WD switch
X72
S3
X201
Accelerator knob
S5
X607
Diagnostic
S9
Lights switch
Y12
S15
Y34
Y35
S29
Y100
S32
Y101
S33
Y102
S34
Y103
S35
Y104
S36
Y105
S41
Y106
S42
Warning switch
Y113
4WD solenoid
S48
Manual-auto switch
Y114
S100
Y202
S101
Y203
S135
S136
Y206
S137
Y207
S138
Y209
S139
S140
S141
S144
Gearshift lever
S604
SB1
ST1
Copyright
SECTION 55 - ELECTRIC SYSTEM
57
CONNECTORS
NAME
DESCRIPTION
NAME
DESCRIPTION
X41
X43
X44
X45
X10
X46
X12
X47
X13
X49
X50
X51
X53
X54
X55
X56
X57
X64
X67
X69
X72
X87
X1
X2
X4
X7
X14
X21
X22
X23
X24
X25
X26
X27
X28
X29
X31
X88
X34
X102
Diode connector
X103
Diode connector
X104
Diode connector
X105
X35
X36
X38
X39
X106
X40
X106
X107
Copyright
58
NAME
DESCRIPTION
NAME
DESCRIPTION
X110
X600
X111
X603
X125
X203
X204
X205
X206
X207
X208
X209
X210
X220
X226
Connector (optional)
X400
X401
X402
X403
X404
X406
X406
X408
X409
X412
X420
X421
Buzzer connector
X608
XC1
XC2
XC3
XC4
XC5
XC6
XX
Diode connector
Copyright
SECTION 55 - ELECTRIC SYSTEM
ENGINE LINE DIAGRAM
59
Copyright
60
Copyright
SECTION 55 - ELECTRIC SYSTEM
SOLENOID VALVE LINE DIAGRAM
61
Copyright
62
Copyright
SECTION 55 - ELECTRIC SYSTEM
LIGHT LINE DIAGRAM
63
Copyright
64
Copyright
SECTION 55 - ELECTRIC SYSTEM
WORK LIGHT LINE DIAGRAM
65
Copyright
66
Copyright
SECTION 55 - ELECTRIC SYSTEM
CAB LINE DIAGRAM
67
Copyright
68
Evaporator box
S45
11-way connector
Potentiometer
Fuse 25 A
10
Speed switch
Blower motor
11
Temperature switch
12
12 V light
Electric cock
X111
9-way connector
X110
Copyright
SECTION 55 - ELECTRIC SYSTEM
BACKHOE ATTACHMENT QUICK COUPLER LINE DIAGRAM
69
Copyright
70
COLD START LINE DIAGRAM
Copyright
SECTION 55 - ELECTRIC SYSTEM
71
INSTRUMENT
Level fuel
Coolant temperature
Battery charge
Transmission
temperature
INPUT
READING
TOLERANCE
320 Ohm
+0/-2 Ohm
185 Ohm
3 Ohm (Ref)
6.5 Ohm
+4/-0 Ohm
193 Ohm
ON
5 Ohm
185 Ohm
OFF
5 Ohm
Can message
0 - 3000 rpm
50 rpm
Can message
3 C ( 37.4 F)
Can message
2 C ( 35.6 F)
Can message
3 C ( 37.4 F)
11 V
16 V
385 Ohm
3 C ( 37.4 F)
149 Ohm
2 C ( 35.6 F)
112 Ohm
3 C ( 37.4 F)
Copyright
72
CN1
PIN
FUNCTION
CN2
NOTE
Not used
Key on power
Wake up
In gear input
Digital input
Driving lights
Digital input
Digital input
Digital input
Not used
Not used
Not used
10
Air conditioning
pressure
Digital input
11
Digital input
12
Menu confirmation
switch input
Digital input
13
UP switch input
14
PIN
FUNCTION
NOTE
Not used
Not used
Buzzer
Not used
Not used
10
Not used
11
Not used
Digital input
12
Not used
Digital input
13
Resistance
15
Cranking
Digital input
14
Thermistor
16
Digital input
Transmission
temperature
17
Not used
15
Not used
18
Parking brake
16
Foot accelerator
0.5 4.5 V
19
Not used
17
Accelerator knob
0.5 4.5 V
20
Minimum
confirmation switch
Digital input
18
Foot accelerator
Output monitored
for diagnostics
21
Decelerator button
Digital input
19
Accelerator knob
Output monitored
for diagnostics
22
Not used
20
Foot accelerator
23
Not used
21
Accelerator knob
24
Not used
22
Not used
25
Transmission oil
pressure
23
Not used
26
Not used
24
Alternator excitation
25
Not used
26
Ground
Digital input
Digital input
Need to fuse at 1
ampere without
disconnect
Digital input
Copyright
SECTION 55 - ELECTRIC SYSTEM
ELECTRIC DIAGRAMS - POWERSHIFT CAB (4WS)
RELAY FUSES
Fuse
no.
Rating
Function
K3
Starting relay
F1A
15 A
K4
F1B
7.5 A
K5
K6
F1C
10 A
K7
K8
15 A
F2A
K9
K10
Optional relay
F2B
15 A
Air conditioning
K10
F2C
15 A
Pilot control
F3A
3A
F3B
3A
F3C
10 A
F4A
7.5 A
F4B
10 A
Backhoe hammer button, bucket level solenoid valve + sensor, transmission disconnect button
F4C
10 A
Backhoe attachment lock, backhoe attachment travel lock, rear work light
switch
F5A
15 A
F5B
10 A
Low beams
F5C
15 A
Main beams
F6A
15 A
Rotating beacon
F6B
7.5 A
F6C
7.5 A
F7A
10 A
F7B
10 A
F7C
6A
F8A
15 A
F8B
15 A
F8C
15 A
73
Copyright
74
COMPONENTS
NAME
DESCRIPTION
NAME
DESCRIPTION
E55
E406
Rotating beacon
E407
E409
E412
Rotating beacon
F1
F2
F3
F4
F5
F112
F113
F500
General fuse
F602
G1
Battery
G67
Alternator
H2
Horn
H7
Reverse buzzer
H26
H606
Buzzer
E3
K14
E18
Roof lamp
K102
E27
K103
Starting
E28
K104
E29
K105
E38
K227
4WD relay
E40
K230
E44
K605
E45
M1
Starter motor
E46
M39
E47
M41
E50
M49
E51
A14
Antitheft unit
A53
Radio (optional)
A105
A401
B4
B5
B25
Foot accelerator
B26
Bucket sensor
B30
B66
B69
B97
B98
B107
B108
B109
Pressure switch
B112
Speed sensor
B608
Accelerator knob
BS1
Left speaker
BS2
Right speaker
E2
Copyright
SECTION 55 - ELECTRIC SYSTEM
NAME
DESCRIPTION
NAME
75
DESCRIPTION
M56
SB1
M57
ST1
M64
ST3
P125
Speedometer (optional)
X17
Seat (optional)
R2
X55
Diagnostic socket
S2
4WD switch
X72
S3
X201
Accelerator knob
S5
X607
Diagnostic
S9
Lights switch
Y12
S15
Y34
Y35
S29
Y91
S32
Y92
S33
Y93
S34
Y94
S35
Y100
S36
Y101
S41
Y102
S42
Warning switch
Y103
S47
Steering selector
Y104
S48
Manual-auto switch
Y105
S100
Y106
S101
Y113
4WD solenoid
S135
Y114
S136
Y202
S137
Y203
S138
S139
Y206
S140
Y207
S141
Y209
S144
Gearshift lever
S404
Copyright
76
CONNECTORS
NAME
DESCRIPTION
X1
X2
X4
X5
X7
X10
X12
X13
X14
X21
X22
X23
X24
X25
X26
X27
X28
X29
X31
X34
X35
X36
X38
X39
X40
NAME
DESCRIPTION
X41
X43
X44
X45
X46
X47
X49
X50
X51
X53
X54
X55
X56
X57
X64
X67
X69
X72
X87
X88
Copyright
SECTION 55 - ELECTRIC SYSTEM
NAME
DESCRIPTION
NAME
77
DESCRIPTION
X91
X400
X92
X401
X93
X402
X94
X95
X403
X96
X404
X97
X98
X406
X102
Diode connector
X406
X103
Diode connector
X408
X104
Diode connector
X105
X409
X106
X412
X106
X420
X107
X421
X110
X600
X111
X603
X125
X606
Buzzer connector
X608
X202
XC1
X203
XC2
XC3
XC4
XC5
XC6
XX
Diode connector
X204
X205
X206
X207
X208
X209
X210
X220
X226
Connector (optional)
Copyright
78
ENGINE LINE DIAGRAM
Copyright
SECTION 55 - ELECTRIC SYSTEM
TRANSMISSION CONTROL UNIT LINE DIAGRAM
79
Copyright
80
Copyright
SECTION 55 - ELECTRIC SYSTEM
SOLENOID VALVE LINE DIAGRAM
81
Copyright
82
Copyright
SECTION 55 - ELECTRIC SYSTEM
LIGHT LINE DIAGRAM
83
Copyright
84
Copyright
SECTION 55 - ELECTRIC SYSTEM
WORK LIGHT LINE DIAGRAM
85
Copyright
86
Copyright
SECTION 55 - ELECTRIC SYSTEM
CAB LINE DIAGRAM
87
Copyright
88
Copyright
SECTION 55 - ELECTRIC SYSTEM
COLD START LINE DIAGRAM
89
Copyright
90
INSTRUMENT
Level fuel
Coolant temperature
Battery charge
Transmission
temperature
INPUT
READING
TOLERANCE
320 Ohm
+0/-2 Ohm
185 Ohm
3 Ohm (Ref)
6.5 Ohm
+4/-0 Ohm
193 Ohm
ON
5 Ohm
185 Ohm
OFF
5 Ohm
Can message
0 - 3000 rpm
50 rpm
Can message
3 C ( 37.4 F)
Can message
2 C ( 35.6 F)
Can message
3 C ( 37.4 F)
11 V
16 V
385 Ohm
3 C ( 37.4 F)
149 Ohm
2 C ( 35.6 F)
112 Ohm
3 C ( 37.4 F)
Copyright
SECTION 55 - ELECTRIC SYSTEM
CN1
PIN
FUNCTION
91
CN2
NOTE
Not used
Key on power
Wake up
In gear input
Digital input
Driving lights
Digital input
Digital input
Digital input
Not used
Not used
Not used
10
Air conditioning
pressure
Digital input
11
Digital input
12
Menu confirmation
switch input
Digital input
13
UP switch input
14
PIN
FUNCTION
NOTE
Not used
Not used
Buzzer
Not used
Not used
10
Not used
11
Not used
Digital input
12
Not used
Digital input
13
Resistance
15
Cranking
Digital input
14
Thermistor
16
Digital input
Transmission
temperature
17
Not used
15
Not used
18
Parking brake
16
Foot accelerator
0.5 4.5 V
19
Not used
17
Accelerator knob
0.5 4.5 V
20
Minimum
confirmation switch
Digital input
18
Foot accelerator
Output monitored
for diagnostics
21
Decelerator button
Digital input
19
Accelerator knob
Output monitored
for diagnostics
22
Not used
20
Foot accelerator
23
Not used
21
Accelerator knob
24
Not used
22
Not used
25
Transmission oil
pressure
23
Not used
26
Not used
24
Alternator excitation
25
Not used
26
Ground
Digital input
Digital input
Need to fuse at 1
ampere without
disconnect
Digital input
Copyright
92
1. 2WD/4WD SWITCH
This switch is used to engage or disengage the
4WD function.
This switch has two positions:
- First position (powershuttle), by pushing button on the left
:
rear wheel drive and braking on rear wheels
(for all gears) (lamp off).
- First position (powershift), by pushing button
on the left
:
rear wheel drive with braking only on rear
wheels (only in first and second gear) (lamp
off);
four wheel drive and braking (in third and
fourth gear) (lamp on).
- Second position (by pushing button on the
right
):
4 wheel drive and braking on 4 wheels (lamp
on).
2. HAND-HELD
AUXILIARY
HYDRAULIC
ATTACHMENT SWITCH (Optional)
This switch has two positions:
- The first position is OFF.
- The second position is ON and enables the
auxiliary hydraulic attachments.
3. LOADER ATTACHMENT SWITCH (Optional)
4. LOADER ATTACHMENT LOCKING SWITCH
(Optional)
When operated, this switch prevents any movement of the loader attachment during travel.
5. ROTATING BEACON SWITCH
This switch is used to turn the rotating beacon
on or off.
Copyright
SECTION 55 - ELECTRIC SYSTEM
6. ROLL-OVER
PROTECTION
SWITCH
(Optional)
This switch is used to engage or disengage the
roll-over protection device. When the operator
is about to start working with the backhoe
attachment in conditions which could cause the
machine to roll over, he/she must activate the
roll-over protection device by pressing the
switch (ON position and lamp turned on).
In this condition, the audible alarm will sound by
means of the buzzer when the pressure switch,
installed on the backhoe attachment boom cylinder, detects a pressure exceeding the following values:
2WS = 116 bar (17 psi)
4WS = 126.5 bar (18 psi)
7. GLIDE RIDE SWITCH (Optional)
The glide ride system control improves the
machine comfort during travel, regardless of
the type of terrain and with the loader bucket
full or empty.
It reduces forward and rearward pitching when
moving rearwards or forwards and when carrying loads, at the same time increasing productivity and operator comfort.
It also reduces impact forces to the machine
during operation.
Do not use this system while operating the
loader attachment.
WARNING
Never operate the glide ride system control when
the loader arm and loader bucket are maintaining
the front of the machine raised off the ground. The
machine could fall and cause serious or fatal injury.
8. MANUAL MODE SELECTION SWITCH
(Powershift transmission)
In situations where manual gearshifting (up or
downshift) is required, the automatic gearshift
of the powershift transmission can be overridden by means of this switch.
NOTE: changing gears up or down must always be
done using the powershift transmission lever.
When the manual mode is no longer required,
place the switch back to the OFF position to return
to automatic gearshifting.
93
9. HORN BUTTON
This button operates the warning horn.
10. HAZARD LIGHT SWITCH
Press the control down to locked position.
The direction indicators and the control will
flash simultaneously.
Press the control down again to turn off the
direction indicators and the lamp.
Copyright
94
1. 2WD/4WD SWITCH
This switch is used to engage or disengage the
4WD function.
This switch has two positions:
- First position (powershuttle), by pushing button on the left
:
rear wheel drive and braking on rear wheels
(for all gears) (lamp off).
- First position (powershift), by pushing button
on the left
:
rear wheel drive with braking only on rear
wheels (only in first and second gear) (lamp
off);
four wheel drive and braking (in third and
fourth gear) (lamp on).
- Second position (by pushing button on the
right
):
4 wheel drive and braking on 4 wheels (lamp
on).
2. HAND-HELD
AUXILIARY
HYDRAULIC
ATTACHMENT SWITCH (Optional)
This switch has two positions:
- The first position is OFF.
- The second position is ON and enables the
auxiliary hydraulic attachments.
3. LOADER ATTACHMENT LOCKING SWITCH
(Optional)
When operated, this switch prevents any movement of the loader attachment during travel.
4. STEER MODE SWITCH
This switch has a locking cover and is used to
select Road, 4 wheel steer or Crab steer.
This switch has three positions:
- Position (a) = Road
- Position (b) = 4 wheel steer
- Position (c) = Crab steer
IMPORTANT: before undertaking any road travel,
select Road mode and fold back the cover to lock
the switch in this position.
Copyright
SECTION 55 - ELECTRIC SYSTEM
5. ROTATING BEACON SWITCH
This switch is used to turn the rotating beacon
on or off.
6. ROLL-OVER
PROTECTION
SWITCH
(Optional)
This switch is used to engage or disengage the
roll-over protection device. When the operator
is about to start working with the backhoe
attachment in conditions which could cause the
machine to roll over, he/she must activate the
roll-over protection device by pressing the
switch (ON position and lamp turned on).
In this condition, the audible alarm will sound by
means of the buzzer when the pressure switch,
installed on the backhoe attachment boom cylinder, detects a pressure exceeding the following values:
2WS = 116 bar (17 psi)
4WS = 126.5 bar (18 psi)
7. GLIDE RIDE SWITCH (Optional)
The glide ride system control improves the
machine comfort during travel, regardless of
the type of terrain and with the loader bucket
full or empty.
It reduces forward and rearward pitching when
moving rearwards or forwards and when carrying loads, at the same time increasing productivity and operator comfort.
It also reduces impact forces to the machine
during operation.
Do not use this system while operating the
loader attachment.
WARNING
Never operate the glide ride system control when
the loader arm and loader bucket are maintaining
the front of the machine raised off the ground. The
machine could fall and cause serious or fatal injury.
95
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96
2. LIGHT SWITCH
This switch has three positions:
- The first position is OFF (control lamp off).
- Second position, by pressing the symbol side
(first click) the instrument cluster panel is
powered, the side lights and the low beam
indicator lamp are turned on (control lamp
on).
- Third position, by pressing the symbol side
again (second click), the high beams are
enabled and the low beams and the high
beam indicator lamp are turned on (control
lamp on).
Copyright
SECTION 55 - ELECTRIC SYSTEM
7. BACKHOE ATTACHMENT QUICK COUPLER
SWITCH (Optional)
You have to press both switches to activate the
quick coupler of the backhoe attachment.
Press
97
Copyright
98
2. LIGHT SWITCH
This switch has three positions:
- The first position is OFF (control lamp off).
- Second position, by pressing the symbol side
(first click) the instrument cluster panel is
powered, the side lights and the low beam
indicator lamp are turned on (control lamp
on).
- Third position, by pressing the symbol side
again (second click), the high beams are
enabled and the low beams and the high
beam indicator lamp are turned on (control
lamp on).
Copyright
SECTION 55 - ELECTRIC SYSTEM
7. MENU SCROLLING SWITCH
By means of this control, it is possible to scroll
through the menu or data options shown on the
diagnostic display.
8. MENU ENTER SWITCH
By means of this control it is possible to display
and confirm the menu options shown on the
display.
9. REAR WINDSHIELD WIPER AND WASHER
SWITCH
This switch has three positions:
- The first position is OFF (lamp off) and both
the windshield wiper and the windshield
washer are disabled.
- The second position allows to press the symbol side of the switch to activate the rear
windshield wiper (lamp on).
- The third position, allows to press the symbol
side of the switch and hold to activate the
windshield washer (lamp on).
When releasing the switch, the windshield
washer stops and the windshield wiper starts
moving.
10. BACKHOE ATTACHMENT SIDESHIFT CARRIAGE HYDRAULIC SHIFTING SWITCH
This button allows hydraulically moving the
backhoe attachment towards the track sides.
Press the button on the upper side of the symbol
99
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SECTION 55 - ELECTRIC SYSTEM
12. FUEL LEVEL GAUGE
This gauge shows the quantity of fuel in the fuel
tank.
13. HOURMETER
The hourmeter shows the number of hours and
tenths of hours the engine has been functioning.
It also makes it possible to determine the intervals of the servicing operations.
14. TACHOMETER
The tachometer shows the engine speed in revolutions per minute.
The figures indicated must be multiplied by 100.
Each intermediate mark shows a value of 100/
rpm.
We recommend not to reach the red line.
The tachometer shows travel speed in kilometres per hour (km/h) and miles per hour (mph).
Road speed in 4th gear with 18.4-26 tyres.
15. TRANSMISSION OIL TEMPERATURE WARNING LAMP
This indicator shows the transmission oil temperature.
When the temperature is normal, the needle is
in the grey area.
If the needle is in the red area, change down to
a lower gear.
If the needle still remains in the red area, stop
the machine travel, place the gearshift lever
and the direction-of-travel control lever in the
neutral position and leave the engine running at
1000/rpm.
If this operation does not enable the oil temperature to be reduced, check the gearbox oil level
and make sure that the radiator and oil cooler
are perfectly clean.
16. ENGINE COOLANT TEMPERATURE GAUGE
This indicator shows the temperature of the
engine coolant solution.
When the temperature is normal, the needle is
in the grey area.
If the needle is in the red area, the audible
warning sounds.
101
Copyright
102
1
1. CAUTION MASTER LAMP
This lamp signals a not critical caution.
When this caution is active, it is necessary to
change the operating mode, plan a down time
to carry out maintenance or, if the fault continues, consult your dealer.
This warning lamp turns on at the same time of
lamps (8), (10), (12) and (14) that indicates a
fault on the machine.
2. SIDE LIGHT AND LOW BEAM INDICATOR
LAMP
This indicator lamp turns on when the side
lights or the low beams are on.
3. MAIN BEAMS INDICATOR LAMP
This indicator lamp turns on when the main
beams are on.
4. DIRECTION INDICATOR LAMP
This lamp turns on when the direction indicators
are working.
5. 4 WHEEL STEER (4WS) INDICATOR LAMP
This lamp turns on when 4 wheel steer mode is
selected and phased.
6. ROAD (4WS) STEER INDICATOR LAMP
This lamp turns on when 2 wheel steer mode is
selected and phased.
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SECTION 55 - ELECTRIC SYSTEM
12. AIR FILTER RESTRICTION LAMP
This warning lamp turns on when the air filter
element needs to be cleaned or replaced.
13. AIR CONDITIONER INDICATOR LAMP
(Optional)
This lamp turns on when the air conditioner is
working.
14. GRID HEATER LAMP (Optional)
If the machine is equipped with a grid heater,
wait for the indicator lamp to turn off before
starting the engine.
15. LOW FUEL LEVEL WARNING LAMP
This warning lamp turns on when the fuel level
is low. You have approximately an hour to fill
the fuel tank.
NOTE: when the starter switch key is in the ON
position, all lamps turn on and the instrument
buzzer sounds for 5 seconds. After this period only
lamp (8) remains alight. The gauges (16) and (17)
set to position.
16. FUEL LEVEL GAUGE
This gauge shows the quantity of fuel in the fuel
tank.
17. BATTERY CHARGE INDICATOR
This indicator shows the state of charge of the
battery.
At normal charge the needle should be in the
grey area.
If the needle is in the left red area, this shows
that the battery charge is insufficient or that the
alternator is not charging the battery.
If the needle is in the right red area, this indicates excessive battery charge which may
cause damage to the battery.
18. DIAGNOSTIC DISPLAY
By means of this display it is possible to visualize the various data of diagnostics. The service
hours are also indicated.
19. TACHOMETER
The tachometer shows the engine speed in revolutions per minute.
The figures indicated must be multiplied by 100.
Each intermediate mark shows a value of
100 rpm.
We recommend not to reach the red line.
103
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104
ANTI-START SYSTEM
A.
B.
C.
D.
M38 Immobiliser
Electronic key socket with LED
2 piece electronic key
+ 50 to ignition
WIRE
No.
FUNCTION
E. Starter motor
F. + 15 key positive
G. Electronic key
CONNECTION
5-6
7-8-9
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SECTION 55 - ELECTRIC SYSTEM
105
Copyright
106
Copyright
SECTION 55 - ELECTRIC SYSTEM
107
SYMBOLS
Work hours
Maintenance
Grid heater
Engine speed
Contaminated fuel
Malfunction
Back-light dimming
Copyright
108
SETUP MENU
Dimmer
Increase
Decrease
Increase
Decrease
Service
interval
Increase
Decrease
Stored error
code
Select / Deselect
Increase
Decrease
Hardware code
Software code
HARDWARE
P/N
ID
VER
SOFTWARE
P/N
ID
VER
Increase
Decrease
Copyright
SECTION 55 - ELECTRIC SYSTEM
109
Go to menu
Normal Key ON
Maximum foot
accelerator: X.X.
Minimum foot accelerator: 113/111
field
X.X.
Maximum accelerator
knob: X.X.
Minimum accelerator
knob: X.X.
125/120
field
Check:
100 mA < Current draw <
1amp
98/88
field
117/120
field
Voltage: XX.X
Transmission oil
temperature: XX
116/124
field
Brakes: XXX
Engine rpm: XXXX
102/92
field
Radiator water
temperature XXX
Air temperature XXX
107/123
field
122/126
field
Check:
100 mA < Current draw < 1 A
Step 11: When LCD test is complete sound alarm for 2 seconds.
Step 12: The following is shown on the LCD display until the key is turned to OFF or the cycle
ends. All gauges and lamps should work as normal and engine will be able to be started.
Copyright
110
Page 1/6
CODE
3059
OCCURRENCE 3
TIME
1004.5
Page 2/6
CODE
3009
OCCURRENCE 2
TIME
1010.6
Page 3/6
CODE
Occurrence counter will be incremented on transition from
inactive to active status. Status has to be stored in EEPROM
and checked at key on. Only the hour count of the last
occurrence will be stored per SAE convention.
1018
OCCURRENCE 1
TIME
1024.5
Page 4/6
CODE
3022
OCCURRENCE 1
HOUR 969
.4
Page 5/6
CODE
3113
OCCURRENCE 2
TIME
1050.6
Page 6/6
CODE
1003
OCCURRENCE 3
TIME
1076.4
Copyright
SECTION 55 - ELECTRIC SYSTEM
111
DIMMING LAW
The dimming adjustment is done through the setup
menu, it can be used in single.
In single step mode, the luminance level go from
min to max value in 10 steps.
The luminance levels of display and gauges always
varies in parallel.
The cluster switches between day and night luminance levels using the work and driving light status,
and is able to manage the display and gauges independently using the same law and customer setting.
Only the night settings can be adjusted since the
day setting of the display is 100% intensity.
During dimming setup the matrix shows the dimming symbol together with the percentage of luminance: its value varies using a step of 10%.
The dimming symbol appears when the proper
menu is selected and stays on the matrix for at
least 2 seconds.
The dot matrix visualization will be as follows:
Copyright
112
WORK HOURS
In order to allow service or the customer to view
vehicle hours of operation, it will not be necessary
to have the key.
By pressing the menu enter/display scroll switch,
with the key turned to OFF, the instrument cluster
panel will activate and display the service hours for
10 seconds.
The hourmeter increments when the engine is running (rpm> 600). The hours are displayed starting
from 0.0 until 210,554,060.7 using an interval of 6
minutes.
In case of battery disconnection, the cluster can
lose 0.1 hour or 6 minutes max.
Work hours
Value may only increase for the hourmeter. While setting the value it can be decreased due to
operator overshoot, but the value can not be stored if it is below the current stored value. Pressing
DISPLAY will exit without saving. ENTER must be pressed to store the modified value in protected
memory.
Copyright
SECTION 55 - ELECTRIC SYSTEM
113
OPERATION
Auto wake up at every 600 ms for sensing a
change in ENTER, DISPLAY, UP or DOWN switch
status will be provided. Upon sensing of one of
those inputs transition, the cluster has to wake up.
Needle collision
control at key-on
At key-on drive all
needles CCW for 1
second
Vibration, service,
transport or
battery loss can
generate a FALSE
If RTZ is observed
on all 5 gauges
TRUE
FALSE
Remove power from gauges:
- engine coolant
- fuel level
Drive gauges:
- engine coolant
- fuel level
Start all normal
display functions
Copyright
114
TACHOMETER
INSTRUMENT
POSITION
0000
0 rpm
Green field
0 2500 rpm
Red field
FFFF
0 rpm
INSTRUMENT
TEMPERATURE
+65 +112 C
(+149 +234 F)
Green field
+65 +106 C
(+149 223 F)
Red field
+106 +112 C
(+223 234 F)
INSTRUMENT
POSITION
00 => FD
FE
Minimum value
FF
Minimum value
An audible alarm must sound when the engine temperature exceeds 106 C (223 F).
In case the sender is disconnected, the gauge has
to go to 65 C (149 F) position.
Reconnecting the sensor the gauge has to return to
the correct position.
Both the movements have to be uniform.
In case of faulty sensor, the instrument will go back
to parking position.
Since this signal is a function of the engine controller the appropriate warning lamp and lamp will be
illuminated.
During cranking, the needle movement shall be frozen in order to inhibit any spurious movement of it.
Copyright
SECTION 55 - ELECTRIC SYSTEM
115
VOLTMETER GAUGE
The oil temp gauge indicates transmission oil temperature from 75 C 115 C (167 239 F).
This gauge is broken up into two ranges, green
and red. The green field goes from 75 C 106 C
(167 223 F).
The red zone is from 105 C 115.5 C (221 240 F).
This gauge will be connected to a sensor that will
provide a specific resistance to correlate to a specific oil temperature.
INSTRUMENT
TEMPERATURE
+75 +115 C
(+167 to +239 F)
Green field
+75 +106 C
(+167 + 223 F)
Red field
+105 +115.5 C
(+221 +240 F)
- 5 V = 75 C (167 F).
The centerline of the pointer will be at 2 angular
degrees from the centerline of the bold reference
mark that indicates this temperature.
- 2.6 V = 93.3 C (200 F).
The centerline of the pointer will be at 3 angular
degrees from the centerline of the bold reference
mark that indicates this temperature.
- 2.05 V = 115.5 C (240 F).
The centerline of the pointer will be at 2 angular
degrees from the centerline of the bold reference
mark that indicates this temperature.
The same range of temperature is used for powershift and powershuttle transmissions.
The gauge will move by 9 angular degrees at keyon in the clockwise position, to replicate the current
instrument cluster behaviour.
This is necessary due to the cool temperatures
present when the unit is working in backhoe position. In case the sender is disconnected, the gauge
has to go down to home position.
Reconnecting the sensor will make the error code
inactive and the gauge has to return to the correct
position.
Both the movements have to be uniform.
A stepper motor will drive the transmission oil temperature gauge. The gauge accuracy should be
less than or equal 2%.
Needle calibration has never to be lost for any
external condition. During cranking, the needle
movement shall be frozen in order to inhibit any
spurious movement of it.
Copyright
116
RED-GREEN
BORDER (Y)
186 Ohm
INDICATED FUEL
LEVEL
30% with 18
angular degrees of
gauge motion
Copyright
SECTION 55 - ELECTRIC SYSTEM
117
WARNING SYSTEM
The diagnostic has to inform the operator regarding
all the operating conditions of the loader backhoe
which are out of range.
These conditions are different from each other:
- warnings;
- error codes;
ALARM ACTIVATION
Non Critical
A failure is present but the operator can continue
his work: the purpose is to warn the operator as
regards the presence of the fault. A beep will sound
every 30 seconds.
Critical
- required action.
Action Required
The display will show the symbol indicating the current problem.
Safety
The system purpose is to warn the operator regarding the presence of a dangerous situation for his
safety. This will be a continuous alarm.
General Sound
There are certain conditions in which it is necessary
to activate an audible alarm. It is a one-second
beep to draw the operators attention to the instrument cluster.
Copyright
118
MAINTENANCE
Two different kinds of maintenance will be available:
- light maintenance;
- heavy maintenance.
LIGHT MAINTENANCE
From 2 hours before the set value, display on the
display the light maintenance symbol at every key
on for 1 second after cranking; after this, the last
selected icon will be visualized on the display. The
hours shown will be the hours when light maintenance is required, not the standard hours displayed
by the hourmeter.
HEAVY MAINTENANCE
From 10 hours before the set value, display on the
display the heavy maintenance symbol at every
key on and should last for 1 second after cranking.
After cranking after this, the last selected icon will
be visualized on the display. The hours shown will
be the hours when light maintenance is required,
not the standard hours displayed by the hourmeter.
Amber-coloured lighting
The interval can be set between 50 and 500 hours
in steps of 100 (0.0, 500, 600, 700, 800, 900,
1000). The 0.0 setting turns the heavy maintenance
feature off.
Amber-coloured lighting
The interval can be set between 50 and 500 hours
in steps of 50 (0.0, 50, 100, 150, 200, 250, 300,
350, 400, 450, 500). The 0.0 setting turns the light
maintenance feature off.
DISPLAY FUNCTION
When the hourmeter reaches the light service interval
3 seconds
3 seconds
GREEN
AMBER
Audible alarm for 1 second when displaying either service interval for the first time
When the hourmeter reaches the heavy service interval
3 seconds
3 seconds
GREEN
AMBER
Audible alarm for 1 second when displaying either service interval for the first time
Since heavy maintenance contains light maintenance the following will be shown:
500 - Light
1000 - Heavy
1500 - Light
2000 - Heavy
The service indicator message will be cleared with a single key cycle
Copyright
SECTION 55 - ELECTRIC SYSTEM
119
WARNING MESSAGES
Function
Engine
coolant
temperature
too high
Engine oil
pressure too
low
Lamp
Alarm
Continuous
Continuous
Lamp
Display
lamp
Condition
DTC
SA
Description
Priority Colour
Coolant above
Coolant
112 C
1002 VCM temperature
1
(234 F) for 5
signal - too high
seconds
Pressure
<26 bar
(377 psi)
500> rpm
Red
Oil pressure
3028 ECU sensor 1
pressure too low
Red
Red
Transmission
oil pressure
too low
Continuous
Malfunction
Continuous
5 seconds
without
message
1051 ECU
Time-out of
message
Red
Malfunction
Continuous
25 seconds
without
message
1053 ECU
Time-out of
message
Red
Malfunction
Continuous
5 seconds
without
message
Time-out of
1054 VCM message engine 1
temperature
Red
Malfunction
Continuous
5 seconds
without
message
Time-out of
1055 VCM message inlet/
exhaust
Red
Malfunction
Continuous
5 seconds
without
message
Time-out of
1056 VCM message engine 1
fluid
Red
Malfunction
Continuous
5 seconds
without
message
Time-out of
1057 VCM message
electric system
Red
Malfunction
Continuous
5 seconds
without
message
1059 VCM
Time-out of
1
message display
Red
Transmission
oil
temperature
too high
Continuous
Transmission
oil above
Transmission oil
115 C
1009 VCM temperature limit 1
(239 F) for 5
reached
seconds
Red
General
display
message
Continuous
Only display
with display
request
Red
Copyright
120
Function
Lamp
Alarm
Lamp
Display
lamp
Condition
DTC
N/A
SA
Description
Priority Colour
VCM
Red
This prevents
VCM damaging the
parking brake
Continuous,
if vehicle is in
gear
Switch closed
N/A
to ground
Red
Brake
temperature
too high
Continuous
Sender
temperature
Warns customer
over 152 C 1006 VCM before brake
2
(306 F) for 5
fade
seconds
Red
Engine oil
pressure too
high
Continuous
Pressure
depends on
speed
Red
Battery charge
voltage too
high
Continuous
3051 ECU
Battery voltage
too high
Red
Battery charge
voltage too
high
Continuous
Supply
Supply battery
source above
1014 VCM voltage above
16 V for 5
16 V
seconds
Red
Battery charge
voltage too
low
Continuous
3052 ECU
Battery voltage
too low
Red
Continuous
Supply
Supply battery
source below
1015 VCM voltage below
11 V for 5
11 V
seconds
Red
Alternator
unable to
charge
Continuous
Alternator L+
terminal
Alternator
1050 VCM
2
under 1.5 V
unable to charge
for 5 seconds
Red
Accelerator
pedal signal
out of range
One second
alarm every
30 seconds
IVS not
changing
state in 300
ms
Foot accelerator
1010 VCM sensor - not
2
plausible
Amber
Accelerator
pedal signal
out of range
One second
alarm every
30 seconds
Accelerator
Foot accelerator
above 4.75 V 1011 VCM sensor -signal
2
for 5 seconds
above range
Amber
Accelerator
pedal signal
out of range
One second
alarm every
30 seconds
Accelerator
Foot accelerator
under 0.25 V 1012 VCM sensor -signal
2
for 5 seconds
below range
Amber
Parking brake
engaged
Battery charge
voltage too
low
3032 ECU
Copyright
SECTION 55 - ELECTRIC SYSTEM
Function
Lamp
Alarm
Lamp
Display
lamp
Condition
DTC
SA
121
Description
Priority Colour
Accelerator
pedal signal
out of range
One second
alarm every
30 seconds
Foot accelerator
1013 VCM sensor - no
2
signal
Amber
Accelerator
pedal signal
out of range
One second
alarm every
30 seconds
Accelerator
Foot accelerator
above 9 V for 1029 VCM sensor - shorted 2
5 seconds
high to Vbat
Amber
Accelerator
pedal signal
out of range
One second
alarm every
30 seconds
Accelerator
Foot accelerator
under 0.5 V 1030 VCM sensor - shorted 2
for 5 seconds
low to Vbat
Amber
5V
accelerator
pedal power
supply
One second
alarm every
30 seconds
Accelerator
Foot accelerator
above 5.1 V 1023 VCM supply voltage
2
for 5 seconds
too high
Amber
5V
accelerator
pedal power
supply
One second
alarm every
30 seconds
Accelerator
Foot accelerator
under 4.9 V 1024 VCM supply voltage
2
for 5 seconds
too low
Amber
5V
accelerator
pedal power
supply
One second
alarm every
30 seconds
Accelerator
Foot accelerator
above 9 V for 1025 VCM supply shorted 2
5 seconds
high to Vbat
Amber
5V
accelerator
pedal power
supply
One second
alarm every
30 seconds
Foot accelerator
Accelerator
supply voltage
under 0.5 V 1026 VCM
2
shorted low to
for 5 seconds
ground
Amber
Accelerator
knob signal
out of range
One second
alarm every
30 seconds
Accelerator
Accelerator
knob sensor above 4.75 V 1035 VCM
signal above
for 5 seconds
range
Amber
Accelerator
knob signal
out of range
One second
alarm every
30 seconds
Accelerator
Accelerator
knob sensor under 0.25 V 1036 VCM
signal above
for 5 seconds
range
Amber
Accelerator
knob signal
out of range
One second
alarm every
30 seconds
Accelerator
1037 VCM knob sensor - no 2
signal
Amber
Copyright
122
Function
Lamp
Alarm
Lamp
Display
lamp
Condition
DTC
SA
Description
Priority Colour
Accelerator
knob signal
out of range
One second
alarm every
30 seconds
Accelerator
Accelerator
knob sensor above 9 V for 1038 VCM
shorted high to
5 seconds
Vbat
Amber
Accelerator
knob signal
out of range
One second
alarm every
30 seconds
Accelerator
Accelerator
knob sensor under 0.5 V 1039 VCM
shorted low to
for 5 seconds
ground
Amber
5V
accelerator
knob power
supply
One second
alarm every
30 seconds
Accelerator
Accelerator
above 5.1 V 1031 VCM knob supply
2
for 5 seconds
voltage too high
Amber
5V
accelerator
knob power
supply
One second
alarm every
30 seconds
Accelerator
Accelerator
under 4.9 V 1032 VCM knob supply
for 5 seconds
voltage too low
Amber
5V
accelerator
knob power
supply
One second
alarm every
30 seconds
Accelerator
Accelerator
knob supply
above 9 V for 1033 VCM
voltage shorted
5 seconds
high
Amber
5V
accelerator
knob power
supply
One second
alarm every
30 seconds
Accelerator
Accelerator
knob supply
under 0.5 V 1034 VCM
voltage shorted
for 5 seconds
low
Amber
Continuous
Switch closed
to ground
with vehicle in N/A
gear and no
parking brake
Amber
Seat not in
driving
position
Boost
temperature
over
Boost air
temperature
too high
One second
alarm every
30 seconds
Engine
coolant
temperature
too high
One second
alarm every
30 seconds
Coolant
Engine over
above 106 C
operating
1019 VCM
(223 F) for 5
coolant
seconds
temperature
Engine
coolant
temperature
too high
One second
alarm every
30 seconds
Coolant
3007 ECU temperature
signal high
88 C
(1276 F) for
5 seconds
Engine over
1018 VCM operating boost
air temperature
Amber
Amber
Amber
Copyright
SECTION 55 - ELECTRIC SYSTEM
Function
Lamp
Alarm
Transmission
oil
temperature
above 105 C
One second
alarm every
30 seconds
Fuel
temperature
too high
One second
alarm every
30 seconds
Fuel
temperature
too high
Lamp
Display
lamp
Condition
DTC
SA
123
Description
Coolant above
Transmission
105 C
1020 VCM over operating
(221 F) for 5
temperature
seconds
Priority Colour
Amber
Fuel over
1021 VCM operating
temperature
Amber
One second
alarm every
30 seconds
Fuel
temperature
3015 ECU
signal source
high
Amber
Fuel
temperature
too high
One second
alarm every
30 seconds
Fuel
3016 ECU temperature
signal no signal
Amber
Clogged air
filter
One second
alarm every
30 seconds
Switch closed
Air filter
to ground for 1001 VCM
threshold
5 seconds
Red
Air
conditioning
not functional
One second
alarm every
30 seconds
Switch closed
Air conditioning
to Vbat for 5 1003 VCM
4
system pressure
seconds
Amber
Hydraulic oil
filter restriction
One second
alarm every
30 seconds
Switch closed
Hydraulic filter
to ground for 1004 VCM
threshold
5 seconds
Red
Fuel
contaminated
with water
One second
alarm every
30 seconds
Display
message
1022 VCM
Amber
Fuel level
sensor
One second
alarm every
30 seconds
Fuel sender
Fuel sender
shorted high above 9 V for 1043 VCM
instrument in
5 seconds
stand-by
Amber
Fuel level
sensor
One second
alarm every
30 seconds
Fuel sender
Fuel sender
shorted low below 0.5 V 1044 VCM
instrument in
for 5 seconds
stand-by
Amber
Fuel level
sensor
One second
alarm every
30 seconds
Input is
switched
battery for 5
seconds
Amber
Fuel over
82 C
(1189 F) for
5 seconds
Fuel sender
open circuit 1045 VCM
instrument in
stand-by
Copyright
124
Function
Lamp
Alarm
Lamp
Display
lamp
Condition
DTC
SA
Description
Priority Colour
Transmission
temperature
sensor
One second
alarm every
30 seconds
Transmission
Transmission
temperature
temperature
sender above 1046 VCM
sender shorted
9 V for 5
high
seconds
Amber
Transmission
temperature
sensor
One second
alarm every
30 seconds
Transmission
Transmission
temperature
temperature
sender below 1047 VCM
sender shorted
0.5 V for 5
low
seconds
Amber
Transmission
temperature
sensor
One second
alarm every
30 seconds
Input is
switched
battery for 5
seconds
Transmission
1048 VCM temperature
open circuit
Amber
Brake
temperature
sensor
One second
alarm every
30 seconds
Brake
Sender over
temperature
1000 Ohm for 1049 VCM
sender out of
5 seconds
range
Amber
General
display
message
One-second
alarm
Only display
VCM with display
request
Amber
Low fuel
warning
One-second
alarm
Amber
Copyright
SECTION 55 - ELECTRIC SYSTEM
125
STARTING SYSTEM
OPERATION
The system includes a key switch, a reinforced wiring, a starter motor and a relay-solenoid valve
assembly.
Copyright
126
Copyright
SECTION 55 - ELECTRIC SYSTEM
RESISTANCE ON THE SYSTEM OF THE STARTER MOTOR
(Voltage lowering)
If the current draw is excessive, it is necessary to
check the system according to the voltage drop
occurring between its single components.
IMPORTANT: disconnect the injection pump fuel
inlet cut-off wire from the solenoid.
Positive cable of the battery
Connect the positive cable of the voltmeter (1) to
the positive terminal of the battery (2).
Connect the negative cable of the voltmeter (1) to
the battery terminal of the starter motor solenoid
valve (3).
Start the starter motor and observe the reading on
the voltmeter. If the voltage drop exceeds 0.2 V,
check and retighten the cable connections. Check
the voltage again. If it is still excessive, replace the
cable.
127
Copyright
128
STARTER MOTOR
TECHNICAL SPECIFICATIONS
Manufacturer .............................................................................................................................................Denso
Voltage .........................................................................................................................................................12 V
Rated power............................................................................................................................................. 2.7 kW
Starting system .......................................................................................................................................Positive
Operating time.............................................................................................................................................. 30 s
Direction of rotation .................................................................................... Clockwise seen from the pinion side
Weight ......................................................................................................................................... 8.4 kg (18.5 lb)
Maximum consumption without load at 11 V and 3000 rpm minimum ...................................... 200 A maximum
Maximum consumption with a torque of 19.6 Nm (14.5 lbfft) at 8 V and 1130 rpm minimum .........600 A maximum
Maximum consumption when shimming at 3 V with a torque of 39.2 Nm (568 lbfft) minimum ......1400 A maximum
MAIN COMPONENTS
1. Motor
2. Induction coils
3. Armature
4. Commutator
5. Brush assembly
6. Pinion gear
7. Intermediate pinion
8. Solenoid
9. Clutch
10. Drive pinion
Copyright
SECTION 55 - ELECTRIC SYSTEM
129
Copyright
130
1. Shim
2. Bearing
3. Armature
4. Bearing
5. Coils housing
6. Protection
7. Brush spring
8. Brush assembly
9. Disc
10. Cover
11. Screw
12. Screw
13. Drain
14. Screw
15. Protection
16. Gasket
17. Washer
18. Nut
19. Rod
20. Connection assembly
21. Screw
22. Connection assembly
23. Nut
24. Ring
25. Roller
26. Cage
27. Pinion
28. Ball
29. Spring
30. Drain
31. Screw
32. Washer
33. O-ring
34. Flange
35. Pinion, rings and spring assembly
36. O-ring
37. Bearing
38. Bearing
39. Spring
40. Shaft
41. Body
42. Clutch assembly
Copyright
SECTION 55 - ELECTRIC SYSTEM
REMOVAL AND INSTALLATION
Disconnect the ground cable (negative) from the
battery.
Remove the rear protection cover and disconnect all
cables connected to the starter motor.
Remove the three retaining screws of the starter
motor and remove the starter motor.
To install the starter motor again, proceed in the
reverse order to that of removal.
131
Copyright
132
Armature
The surface of the commutator must be clean and
without traces of burns. If necessary, remove traces
of burns using fine sandpaper. Do not use emery
cloth. Then, clean the commutator with a cloth
soaked in gasoline.
After rectifying the commutator, polish it with fine
sandpaper, then wipe it with a cloth soaked in gasoline.
NOTE: make sure not to graze the metal of the commutator during rectification of insulating notches.
The resistance of the armature insulation may be
checked by connecting an ohmmeter (1) between
the blades of the commutator (2) and the armature
shaft (3). The resistance must be infinite (no continuity).
To check that the armature is not short-circuited, a
special device for armatures must be used. The
other solution is to replace the armature.
If the circumference of the armature has come into
contact with the starter pole shoes, the bearings of
the armature are probably excessively worn out.
First check that the starter pole shoes have been
tightened and that the armature rotates without any
concentric defect. If necessary, replace the armature bearings.
Field coils
To check the resistance of the field coil insulation,
connect an ohmmeter (1) between the brushes of
each induction coil (2) and a clean unpainted area
of the body (3). The resistance must be infinite (no
continuity).
To check the continuity of the field coils, connect an
ohmmeter between the brushes of each induction
coil and the main supply terminal (the thickest
braided wire). The resistance must be equal to 1
MW.
If the field coils are defective, the entire assembly
consisting of the body and the field coils must be
replaced.
Drive pinion
The drive pinion must only rotate clockwise. If the
pinion is seized or turns in both directions or if its
teeth are damaged, change the complete drive
assembly.
NOTE: if the teeth of the drive pinion are damaged,
also check the teeth of the engine flywheel ring
gear.
Copyright
SECTION 55 - ELECTRIC SYSTEM
133
TROUBLESHOOTING
STARTING SYSTEM
The motor does not start when the starter switch key is operated and the transmission is in the neutral position.
Is the battery properly charged?
NO
YES
Check the starter motor wiring. Are there bad
connections, cut or stripped cables?
YES
NO
Is the starter motor seized?
YES
NO
Operate the starter switch key. Is there
a voltage of +12 V on the (white) input
wire of the starting solenoid valve
(terminal 30)?
YES
YES
NO
NO
Check the starter motor relay (K01). Can you hear
the relay operate after operating the starter switch
key?
NO
Solenoid possibly
defective. Remove the
starter motor and inspect.
Remove the connector from the relay (K01). Is there a voltage of +12 V
YES
at terminal 86 (white/black) after the starter switch key is operated?
NO
Check the starter motor safety relay (K3). Can one hear the relay
operate after operating the reverse travel lever?
NO
Remove the connector from relay K3. Is there a voltage of +12 V at
terminal 86 (white/black) after the reverse travel lever is operated?
YES
NO
Are the cable wires of the reverse travel lever properly
connected?
YES
Does the reverse travel lever switch operate correctly?
NO
NO
NO
YES
Are the indicators on the instrument panel correctly lighted
after operating the key switch?
YES
Are the cable wires of the key switch connected correctly?
YES
Replace the key switch.
NO
Reconnect the wires to the key switch.
Copyright
134
STARTER MOTOR
TROUBLE
The starter motor does not run
(the magnetic switch makes no
operating noise).
CAUSE
ACTION
The starter motor runs too slowly. Poor magnetic switch contact.
Sliding clutch.
Anomalous noise.
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SECTION 55 - ELECTRIC SYSTEM
135
ALTERNATOR
TECHNICAL SPECIFICATIONS
Rated voltage ............................................................................................................................................ 14.5 V
Current ...................................................................................................................................................... 120 A
Swing speed ........................................................................................................................ 12000 13500 rpm
Operating temperature ...................................................................................... -30 C 90 C (-435 1305 F)
Direction of rotation .................................................................................... Clockwise seen from the pulley side
Regulated voltage at 5000 rpm with 10 A at 25 C (362 F) .......................................................... 14.2 14.8 V
Maximum load that can be applied at terminal L ........................................................................ 12 V, 3.4 W x 6
Copyright
136
OPERATION
The alternator, installed on the motor, on the front
RH side of the vehicle, is driven by the crankshaft
pulley with the help of a belt.
The alternator contains built-in regulators.
Current draw on the starter motor system:
When the ignition key is turned, a current of low
intensity is sent by the battery to the field winding of
the rotor (terminal IG).
At this stage, the indicator lamp (terminal L) turns
on and the rotor is partially magnetized.
When the motor starts and the partially magnetized
rotor rotates inside the stator, a three-phase alternating current is generated (terminal B+).
A constant portion of this current is transformed into
a direct current by three excitation diodes installed
in the rectifier.
The direct current is sent as reinforcement through
the field winding of the rotor.
Using this method an increase in the magnetic field
of the rotor is obtained, as well as a rapid rise in the
voltage and current generated at the output.
The luminosity of the indicator lamp decreases
when the voltage generated at the output is increasing (terminal L).
The indicator lamp goes out when the voltage at terminal L is equal to that of the battery.
The voltage continues to increase up to the value
predefined by the regulator.
In case the alternator belt is broken, the voltage
does not accumulate in the alternator and the load
indicator lamp remains lighted to indicate the problem.
1. Terminal W
2. Terminal IG
3. Terminal L
4. Terminal B
Copyright
SECTION 55 - ELECTRIC SYSTEM
137
TROUBLESHOOTING
TROUBLE
Not recharged.
Recharge insufficient.
Excessive recharge.
CAUSE
ACTION
Worn brushes.
Short-circuited diodes.
Copyright
138
BATTERY
For the loader backhoe models two different kinds of installation are provided:
- with one battery;
- with two batteries (for cold climates).
TECHNICAL SPECIFICATIONS
Single battery
Voltage: ........................................................................................................................................................12 V
Capacity (20 h):.......................................................................................................................................... 95 Ah
Discharge current: ...................................................................................................................................... 900 A
Weight with electrolyte: ................................................................................................................... 25 kg (55 lb)
Double battery
Voltage: ........................................................................................................................................................12 V
Capacity (20 h):.......................................................................................................................................... 60 Ah
Discharge current: ...................................................................................................................................... 600 A
Weight with electrolyte: ................................................................................................................ 17 kg (37.5 lb)
OPERATION
All models feature one or two 12 V, negative
ground, maintenance free lead calcium (Pb-Ca)
type battery.
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SECTION 55 - ELECTRIC SYSTEM
REPLACEMENT
Move the machine to a level and firm ground.
Lower the loader attachment to the ground.
Place the backhoe attachment in the road travel
position.
Place the direction-of-travel lever and gearshift lever
in neutral position.
Immobilize the machine by means of the parking
brake.
Stop the engine and remove the starter key.
WARNING
Never reverse the battery terminals. Connect the
positive cable to the positive terminal (+) and the
negative cable to the negative terminal (-).
When disconnecting the battery cables, always disconnect the negative cable (-) first.
When reconnecting the battery cables, always connect the negative (-) cable last.
Never short-circuit the battery terminals with metal
objects.
Never touch the battery terminals with your hands.
This could generate an electrolysis inside the
human body and damage the bodys vital organs.
Place the battery switch in the OFF position.
Remove the battery master switch support (6) without disconnect the battery cables.
Remove the terminal covers and disconnect the
cables, first from the negative terminal (1) then the
positive terminal (2).
Remove the nuts and washers (3), the clamping bar
(4) and the brackets (5) and remove the old battery.
Install the new battery.
Install the brackets (5), the clamping bar (4) and the
washers and nuts (3).
Clean the cables and the connecting terminals and
coat them with grease.
Connect the cables, first to the positive terminal (2),
then the negative terminal (1) and install the terminal covers.
Reassemble the battery master switch support (6).
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WARNING
Antidote:
EXTERNAL: rinse well with water, removing any
soiled clothing.
CHARGE CHECK
WARNING
ELECTROLYTE CONCENTRATION
WARNING
Batteries produce explosive gases. To prevent any
risk of explosion, observe the following instructions:
in kg/dm3 (lb/ft3)
Charge
Normal
Tropical
1.28 (80)
1.23 (77)
good
1.20 (75)
1.12 (70)
reduced: charge
1.12 (70)
1.08 (67)
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141
WARNING
Connecting jumper cables wrongly or shortcircuiting battery terminals can cause an accident.
Connect the jumper cables following the instructions in this manual.
IMPORTANT: make sure that the voltage of the
booster batteries is the same as that of the machine
system (12 V).
Open the battery box and then remove the tool box.
Remove the terminal covers.
Connect the positive (+) jumper cable to the positive
(+) terminal of the machines battery.
Connect the negative (-) jumper cable to one of the
fastening screws (1) of tank.
Start the engine
First disconnect the negative (-) jumper cable, then
disconnect the positive (+) jumper cable from the
booster battery.
Install the terminal covers.
Install the tool box and close the battery box.
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TROUBLESHOOTING
TROUBLE
The electric system is
inoperative.
POSSIBLE CAUSE
ACTION
Dead batteries.
Loose belt.
Malfunctioning battery.
Malfunctioning alternator.
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SECTION 55 - ELECTRIC SYSTEM
TROUBLE
Batteries will not charge.
POSSIBLE CAUSE
143
ACTION
Sulphated batteries.
Malfunctioning alternator.
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NOTES:
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580ST
590ST
695ST
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SECTION 82 - LOADER ATTACHMENT
WARNING
Before using the controls make sure that the operators seat is correctly adjusted in the loader attachment position.
WITH STANDARD LOADER BUCKET
Located on the right of the steering wheel, this nine
position lever operates all the loader attachment
controls.
The speed of movement of each control depends on
the angle to which the lever is tilted. In the intermediate position, two movements can be obtained
simultaneously.
WITH 4x1 LOADER BUCKET
The function of the lever is identical to that of the
machine fitted with the standard loader bucket, with
the addition of the clam control.
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SECTION 82 - LOADER ATTACHMENT
FILLING THE LOADER BUCKET
With the lever in position (4), the bucket rolls back
(fills).
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SECTION 82 - LOADER ATTACHMENT
Lift and remove the top portion (3) of the roller
switch, rotate it by 180 and tighten the screw in the
top portion of the roller.
NOTE: the open U shape must point downwards.
Carefully restore the screw (2) into place and do not
overtighten.
Test the switch by lifting it up into detent position
before restoring the cap into place. The switch
should lock into position.
In this condition, the 4x1 loader bucket control roller
is locked. To unlock it, it is necessary to rotate the
top portion again and take it back to its initial position.
WARNING
Before leaving the operators compartment, undertaking any road travel or working with the backhoe
attachment, place the pin in locking position.
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BUCKET SELF-LEVELLING
SELF-LEVELLING ADJUSTMENT
The return to dig device is an electrically activated
feature which enables the operator to automatically
return the bucket to a level digging position for a further work cycle, with one simple movement of the
control lever (3).
Whenever the bucket is rolled forward to dump the
return to dig electric circuit is completed and the
solenoid on the bucket spool is energised.
When the loader bucket control lever (3) is moved
diagonally left to the return to dig position (2) the
electromagnet will hold the bucket spool in the roll
back position until the bucket is in the level digging
position at which time the indicator on the rod of the
bucket linkage will pass in front of the sensor which
de-energises the electromagnet on the bucket spool
enabling the spool to return to the neutral position.
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SECTION 82 - LOADER ATTACHMENT
UNLOCKED POSITION
Extract the pin (2) from the hole (4) in the safety
strut (1).
Lower the loader attachment.
Place the safety strut (1) to storage position: align
the holes of the safety strut (1) and bracket (5) and
assemble the pin (2).
Fasten the pin (2) by installing the split pin (3).
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WARNING
It is mandatory to install the safety strut when carrying out any operation requiring the loader attachment to be in the raised position.
1
UNLOCKED POSITION
Remove the flip (3) and the strut (2) from the cylinder rod.
2
Install the safety strut (2) on the loader arm by
means of the split pins (1).
Start the engine and lower the loader attachment.
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SECTION 82 - LOADER ATTACHMENT
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WARNING
Always wear eye protection when using a tool
which might project metal particles. Use a hammer
with a soft face, such as copper, for pins assembly/
disassembly.
(4x1 bucket) disconnect and plug the hydraulic supply lines.
Start the engine.
Operate the attachment controls so as to release
the bucket.
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WARNING
When using the forks with a 4x1 bucket, never
attempt to use the bucket jaw opening function.
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SECTION 82 - LOADER ATTACHMENT
INSTALL THE FORKS IN REST POSITION
Rest the loader bucket on a level and firm ground.
Stop the engine and remove the starter key. Disengage the parking brake lever.
Remove the retained pin and the pin (1).
Tilt the fork (2) manually and carefully until it is rearwards into transport position.
Reinstall the pin (1) and the safety pin into their
housing.
NOTE: if necessary, slide the fork to the side to
bring it into its housing.
Repeat the same operations for the other fork.
IMPORTANT: the forks must be securely retained in
their proper storage position using the pins and split
pins provided for this purpose. If forks are not correctly secured, they can cause serious injury.
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LOADER REMOVAL
Remove the loader
described previously).
bucket
(see
procedure
Remove the snap rings (3) and drive out the pins
(4).
Lower the arms onto the lift cylinders.
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SECTION 82 - LOADER ATTACHMENT
Support loader using a suitable sling.
Remove the snap ring and the pin, then extract the
pin (8).
INSTALLATION
For installation, follow the removal procedure in
reverse order.
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590ST
695ST
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SECTION 84 - BACKHOE ATTACHMENT
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SECTION 84 - BACKHOE ATTACHMENT
The backhoe attachment on the hydraulic control
models is controlled using two rear hydraulic control
levers (9) and (10).
The telescopic dipper on pilot control modes is controlled using the two buttons (12) and (13) on the left
hydraulic control lever.
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WARNING
Check control functions before operating the
machine. Failure to check control pattern before
operating can cause unexpected machine movement, death or serious injury.
WARNING
Any uncontrolled movement of the machine can
cause an accident. Before turning the operators
seat to the backhoe attachment working position, it
is essential to place the direction-of-travel control
lever and the powershuttle gearshift lever in the
neutral position and immobilize the machine by
means of the parking brake lever.
WARNING
Before using the backhoe controls, make sure that
the operators seat is correctly adjusted in the backhoe attachment position.
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SECTION 84 - BACKHOE ATTACHMENT
BACKHOE ATTACHMENT MECHANICAL
CONTROLS
STABILIZER MECHANICAL CONTROLS
IMPORTANT: whenever the backhoe attachment is
used, the machine must be resting on the stabilizers.
Left-hand stabilizer left-hand control lever
This lever has three positions:
Position (0): neutral. This position stops the movement of the left-hand stabilizer. As soon as the lever
is released, it automatically returns to the neutral
position (0) and the left-hand stabilizer stops raising
or lowering.
Position (1): the left-hand stabilizer lowers.
Position (2): the left-hand stabilizer rises.
Right-hand stabilizer right-hand control lever
This lever has three positions:
Position (0): neutral. This position stops the movement of the right-hand stabilizer. As soon as the
lever is released, it automatically returns to the neutral position (0) and the right-hand stabilizer stops
raising or lowering.
Position (1): the right-hand stabilizer lowers.
Position (2): the right-hand stabilizer rises.
NOTE: to raise or lower the two stabilizers at the
same time, operate the two levers simultaneously.
IMPORTANT: before machine travel or before using
the loader attachment, make sure the stabilizers are
completely raised.
During road travel, the stabilizers must be completely raised and immobilized by means of the pins
provided for that purpose.
Locking the stabilizer mechanical controls (specific to certain countries)
This pin (1), located in front of the stabilizer control
levers, is used to lock the stabilizer controls.
To lock the controls, extract the pin from its housing
and insert it into the specially provided hole of the
lever support.
WARNING
Before leaving the operators compartment, undertaking any road travel or working with the backhoe
attachment, place the pin in locking position.
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SECTION 84 - BACKHOE ATTACHMENT
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ISO configuration
Backhoe dipper and backhoe attachment swing lefthand control lever
This lever has five positions:
Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as
the lever is released, it automatically returns to the
neutral position (0) and the attachment remains in
the position where it was when movement stopped.
Position (A): the backhoe dipper extends.
Position (B): the backhoe dipper retracts.
Position (C): the backhoe attachment swings to the
left.
Position (D): the backhoe attachment swings to the
right.
Backhoe boom and backhoe bucket right-hand control lever
This lever has five positions:
Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as
the lever is released, it automatically returns to the
neutral position (0) and the attachment remains in
the position where it was when movement stopped.
Position (E): the boom lowers.
Position (F): the boom rises.
Position (G): the backhoe bucket closes.
Position (H): the backhoe bucket opens.
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SECTION 84 - BACKHOE ATTACHMENT
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SECTION 84 - BACKHOE ATTACHMENT
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Cross-pattern configuration
Backhoe boom and backhoe attachment swing lefthand control lever
This lever has five positions:
Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as
the lever is released, it automatically returns to the
neutral position (0) and the attachment remains in
the position where it was when movement stopped.
Position (A): the boom lowers.
Position (B): the boom rises.
Position (C): the backhoe attachment swings to the
left.
Position (D): the backhoe attachment swings to the
right.
Backhoe dipper and backhoe bucket right-hand
control lever
This lever has five positions:
Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as
the lever is released, it automatically returns to the
neutral position (0) and the attachment remains in
the position where it was when movement stopped.
Position (E): the backhoe dipper extends.
Position (F): the backhoe dipper retracts.
Position (G): the backhoe bucket closes.
Position (H): the backhoe bucket opens.
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SECTION 84 - BACKHOE ATTACHMENT
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SECTION 84 - BACKHOE ATTACHMENT
BACKHOE ATTACHMENT MECHANICAL
CONTROL LOCK
(Specific to certain countries)
This pin (1), located in front of the stabilizer control
levers, is used to lock the backhoe attachment controls.
WARNING
Before leaving the operators compartment, undertaking any road travel or working with the backhoe
attachment, place the pin in locking position.
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3. RIGHT-HAND
HYDRAULIC
CONTROL
LEVER: the right-hand hydraulic control lever
controls the bucket and the boom or the dipper
(depending on the control pattern adopted).
4. STABILIZER CONTROLS: the right-hand control is for the right-hand stabilizer and the lefthand control is for the left-hand stabilizer.
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SECTION 84 - BACKHOE ATTACHMENT
CONTROL ENABLE SWITCH
This control is located on the right-hand control
lever.
This switch has three positions:
- position OFF: (lamp off) all controls will deactivate;
- position (1): by pressing the upper side (lamp off),
the stabilizers will activate;
- position (2): by pressing the upper side (lamp on)
again, all controls will activate.
WARNING
After using the attachment or before leaving the
machine, always tilt the switch to OFF by pressing
the lower side of the switch (lamp off). Never forget
this basic safety requirement.
NOTE: when starting the engine, the position OFF
for disabled controls is automatically selected.
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SECTION 84 - BACKHOE ATTACHMENT
STABILIZER HYDRAULIC CONTROLS
These controls are located on the left-hand hydraulic control lever and may be operated independently
or simultaneously. These controls are proportional,
and therefore, the stabilizer speed may vary.
IMPORTANT: whenever the backhoe attachment is
used, the machine must be resting on the stabilizers.
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SECTION 84 - BACKHOE ATTACHMENT
AUXILIARY BI-DIRECTIONAL CONTROLS (Optional)
Press and hold the left-hand button (1) to let the oil
flow out of the left-hand side of the boom.
Press and hold the left-hand button (2) to let the oil
flow out of the right-hand side of the boom.
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Operate the backhoe attachment controls alternately so as to slide the sideshift carriage sideways.
Once the attachment is in the side position required,
swing it round into alignment with the machine.
Work on the opposite side of the sideshift carriage
as much as possible. Otherwise, reduce the load in
the bucket for better stability.
Press the backhoe attachment sideshift locking
switch (1). The switch lamp turns off (OFF position).
IMPORTANT: except when the sideshift carriage is
being moved, the switch (1) must always be in the
OFF position. Never use the backhoe attachment
with the sideshift carriage unlocked.
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SECTION 84 - BACKHOE ATTACHMENT
HYDRAULIC HANDLING
Press the backhoe attachment sideshift unlocking
switch (1). The switch lamp turns on (ON position).
(A) Version with mechanical engines
(B) Version with electric engines
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WARNING
Always support the structural members so that they
will be stable and safe to work around.
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SECTION 84 - BACKHOE ATTACHMENT
Disconnect the yoke of the lock cylinder (1) for
transport from the hook (2).
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WARNING
Always wear eye protection when using a tool
which might project metal particles.
Restart the engine.
Operate the backhoe attachment controls so that
the hook (4) releases from the pin (5).
Stop the engine and remove the starter key.
INSTALLATION
Start the engine.
Slowly approach the arm to the backhoe bucket
paying attention that hook (4) engages in the bucket
pin (5).
Move the arm so that the pin hole (3) aligns with the
holes of the bucket lugs.
Stop the engine and remove the starter key.
Insert pin (3) and install the stop ring (1) and the ring
(2).
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SECTION 84 - BACKHOE ATTACHMENT
BACKHOE BUCKET
Move the machine to a level and firm ground.
Position the backhoe bucket so that the bucket teeth
can be replaced.
Place the direction-of-travel lever and gearshift lever
in neutral position.
Immobilize the machine by means of the parking
brake.
Stop the engine and remove the starter key.
WARNING
Nobody must be in the trajectory of the tooth holder
and of the tooth to be removed.
During tooth removal, both the tooth holder and the
tooth could be unexpectedly projected, thus hitting
persons standing in their trajectory or nearby.
Projected metal chips could hit persons and cause
injury.
Remove the tooth holder (2) using a hammer and a
chisel.
Remove the tooth (1) from the tooth holder (3).
Clean the inside of the tooth holder, removing any
dirt or rust.
Insert a new tooth (1) into the tooth holder (3).
Lock the new tooth by installing the tooth holder (2).
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CONTROLS
Press the backhoe attachment sideshift unlocking
switch (1). The switch lamp turns on (ON position).
(A) Version with mechanical engines
(B) Version with electric engines
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SECTION 84 - BACKHOE ATTACHMENT
HYDRAULIC DIAGRAM
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12. Washer
13. Spacer
14. Spacer
15. Snap ring
16. Pin
17. Cylinder support
18. Handling cylinder
19. M8 x 14 hex screw
20. Shim
21. Washer
22. Shoe
23. Shim
24. Fitting
25. M12 x 20 socket head screw
26. Shoe
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SECTION 84 - BACKHOE ATTACHMENT
HANDLING CYLINDER
1. Stroke
2. Completely retracted
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NOTES: