580sn, N, WT 590sn N t3 Serv

SERVICE MANUAL
580N
580SN WT
580SN
590SN
47365539 08/07/2012
EN
Contents
INTRODUCTION
Engine....................................................................................... 10
Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001
Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.216

Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400
Exhaust Gas Recirculation (EGR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.501
Transmission.............................................................................. 21
Power Shuttle transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.112
Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.113
Power Shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.134
Powershift transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.135
Power Shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.154
Powershift transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.155
Front axle system ....................................................................... 25

Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.100
Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.102
Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.108
Non-powered front axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.400
Rear axle system........................................................................ 27

Powered rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.100
Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.106
Planetary and final drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.120
Brakes and controls .................................................................... 33

Parking brake / Parking lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.110
Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.202
Hydraulic systems....................................................................... 35
Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.000
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Pump control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.102
Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.106
Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.204

Reservoir, cooler, and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.300
Safety and main relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.350
Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.359

Auxiliary hydraulic valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.525
Stabilizer hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.703
Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.723
Excavator and backhoe hydraulic controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.726
Boom hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.736
Dipper hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.737
Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.738
Swing arm hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.739
Telescopic arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.740
Frames and ballasting ................................................................. 39

Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.100
Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.129
Steering..................................................................................... 41
Steering control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.101
Hydraulic control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.200
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.216
Wheels ...................................................................................... 44
Front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.511
Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.520
Cab climate control ..................................................................... 50

Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.200
Electrical systems ....................................................................... 55
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Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.024
Harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.100

Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.302
External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.404
Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.408
Cab/Platform harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.510

Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.525
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.DTC
Front loader and bucket............................................................... 82

Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.100
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.300
Booms, dippers, and buckets ....................................................... 84

Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.100
Boom pivoting support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.114
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.910
Dipper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.912
Platform, cab, bodywork, and decals ............................................. 90

Machine shields and guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.105
Protections - ROPS and FOPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.114

Pneumatically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.124
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.150
Cab interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.151
Cab doors and hatches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.154
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INTRODUCTION
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Contents
INTRODUCTION
Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N NA, 580SN NA, 580SN WT NA, 590SN NA
Safety rules - Ductile iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Battery - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

580N NA T4, 580SN NA T4, 580SN WT NA T4, 590SN NA T4
Basic instructions - Fuse and relay locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Basic instructions Fuse, relay and diode icon definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Basic instructions - Diagnostic service tool port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

580N, 580N NA, 580SN, 580SN NA, 580SN WT, 580SN WT NA, 590SN, 590SN NA
Basic instructions - Welding on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Cab heater - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Torque - Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Abbreviation Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Safety rules
DANGER
Improper operation or service of this machine can result in an accident.
Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have
read and understood the operation, lubrication, maintenance, and repair information.
Failure to comply will result in death or serious injury.
D0010A
WARNING
Maintenance hazard!
Always perform all service procedures punctually at the intervals stated in this manual. This ensures
optimum performance levels and maximum safety during machine operation.
Failure to comply could result in death or serious injury.
W0132A
WARNING
Pressurized system!
Before attempting any service procedure, it is your responsibility to know the number of accumulators
on the machine, and the correct procedure for releasing the pressure of each accumulator.
W0136A
NOTICE: Extreme working and environmental conditions require shortened service intervals.
Use Case fluids, lubricants, and filters for the best protection and performance of your machine. All fluids, lubricants,
and filters must be disposed of in compliance with environmental standards and regulations. Contact your dealer with
any questions regarding the service and maintenance of this machine.
Read the safety decals and information decals on the machine. Read the Operator’s Manual and safety manual.
Understand the operation of the machine before you start any service.
Before you service the machine, put a 'Do Not Operate' tag on the steering wheel or over the key switch. Ensure the
tag is at a location where everyone who might operate or service the machine may see clearly. One tag is included
with your new machine. Additional tags are available from your dealer.
Plastic and resin parts

• Avoid using gasoline, paint thinner, etc. when cleaning plastic parts, console, instrument cluster, etc.
• Use only water, mild soap, and a soft cloth when you clean these parts.
• Using gasoline, thinners, etc. can cause discoloration, cracking, or deformation of the part being cleaned.
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INTRODUCTION
Safety rules - Ductile iron

DANGER
Improper operation or service of this machine can result in an accident.
Any unauthorized modifications made to this machine can have serious consequences. Consult an
authorized dealer on changes, additions, or modifications that may be required for this machine. Do
not make any unauthorized modifications.
D0030A
Before you weld, cut, or drill holes on any part of this machine, make sure the part is not cast ductile iron. See your
dealer if you do not know if a part is cast ductile iron. The following are cast ductile iron parts:
• two wheel drive steering link
• dump links
• front axle
• stabilizers
• extendahoe
• swing
• bucket linkage
• Air Conditioning (A/C) compressor mounting bracket
Unauthorized modifications to cast ductile iron parts can cause injury or death. Welding, cutting, or drilling can cause
cast ductile iron to break. Do not weld, cut, or drill to repair or to attach items to cast ductile iron parts on this machine.
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INTRODUCTION
Safety rules
Unless otherwise instructed, always perform these steps before you service the machine:
1. Park the machine on a flat, level surface.
2. Place the backhoe in the transport position with the swing lock pin installed for transport.
3. Place the loader bucket on the ground, with the bottom of the loader bucket parallel to the surface.
4. Place the direction control lever and the transmission in neutral.
5. If you need to open the hood to perform service, raise the loader arms and install the support strut.
6. Shut down the engine.
7. Place a 'Do Not Operate' tag on the key switch so that it is visible to other workers or remove the key.
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INTRODUCTION
Basic instructions - Important notice regarding equipment servicing

All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel,
strictly complying with the instructions given, and using, whenever possible, the special tools.
Anyone who performs repair and maintenance operations without complying with the procedures provided herein
shall be responsible for any subsequent damages.
The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or
local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manu-
facturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.
In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case
of damages caused by parts and/or components not approved by the manufacturer.
The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for
continuous improvement. Some information could not be updated due to modifications of a technical or commercial
type, or changes to the laws and regulations of different countries.
In case of questions, refer to your CASE CONSTRUCTION Sales and Service Networks.
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INTRODUCTION
Battery - Basic instructions

WARNING
Explosive gas!
Batteries emit explosive hydrogen gas and other fumes while charging. Ventilate the charging area.
Keep the battery away from sparks, open flames, and other ignition sources. Never charge a frozen
battery.
W0005A
WARNING
Hazardous chemicals!
Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation
and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash
hands after handling.
W0006A
• Do not run the engine with the alternator wires disconnected.

• Before using an electric welder, disconnect the alternator wires, instrument cluster and batteries. Disconnect
the ECU connectors.
• Do not use a steam cleaner or a cleaning solvent to clean the alternator.
• Keep the battery vents clean. Ensure the battery vents are not restricted.
Disconnect battery
1. Remove the battery cover hardware.
RCPH11TLB001AAM 1
2. Remove the battery cover.
RCPH11TLB002AAM 2
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3. Disconnect the negative battery cable from the neg-

ative battery terminal.
RCPH11TLB003AAM 3
Master disconnect switch (if equipped)

Enable or disable electrical power from the machine bat-
teries to the electrical components using the master dis-
connect switch, located on the right hand side of the en-
gine.
NOTICE: Wait at least 60 seconds after ignition key is
placed in the OFF position before turning master discon-
nect switch to OFF. This allows the machine controllers to
shutdown properly.
NOTICE: Some machine service procedures require an
actual terminal disconnect of the batteries. Do not use the
master disconnect for those types of procedures, such as
welding on the machine.
RCPH11TLB002BAD 4
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INTRODUCTION
Basic instructions - Fuse and relay locations

The machine is equipped with four fuse box locations. Two locations in the front console, a side console box and an
external location.
Front console box

1. Turn the thumb screw (1) to loosen the panel cover
(2) for the fuse box. Remove the panel cover.
RCPH10TLB320AAF 1
2. Remove the fuse box cover.
RCPH10TLB307AAF 2
RCPH10TLB303AAF 3
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INTRODUCTION
3. Refer to the decal on the interior side of the panel

cover for fuse, relay, and/or diode functions.
RCPH10TLB310AAF 4
Front console ECU fuse and relay

1. Remove the cover from the steering column shroud.
RCPH11TLB012BAD 5
Fuse or relay Designation

reference
(1) ECU B+ relay
(2) ECU B+ 20 A fuse
(3) ECU B+ 7.5 A fuse
(4) LAMBDA SENSOR B+ 7.5 A fuse
RAPH12TLB0016BA 6
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INTRODUCTION
Side console box

1. Turn the thumb screws (1) to loosen the panel cover
RCPH10TLB437AAF 7
2. Remove the fuse box covers as needed.
RCPH10TLB301AAF 8
RCPH10TLB302AAF 9
3. Refer to the decal on the interior side of the panel

cover for fuse, relay, and/or diode functions.
RCPH10TLB319AAF 10
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INTRODUCTION
Glow-plug Control Unit (GCU) fuse

1. Raise the loader arm and engage the safety support.
2. Lift the engine hood.
3. Locate the 60 A fuse box for the GCU on the right
hand side of the engine attached to the cab frame.
RAPH12TLB0017BA 11
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INTRODUCTION
Basic instructions Fuse, relay and diode icon definitions

Right hand side console panel

Power Shuttle Powershift
RAIL12TLB0018CA 1 RAIL12TLB0019CA 2
Fuse icon definitions

Symbol Function
ECU B+
Instrument cluster key ON
Instrument cluster B+
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INTRODUCTION
Symbol Function
Rear lights
Rear wipers/washers
Transmission differential lock
Tail lights
Pilot controls
Cigarette lighter plugs
4WD, Auto Ride Control
Dome light
Radio B+
Horn
Blower motor
A/C
TRAX B+
Key switch
Air seat
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INTRODUCTION
Symbol Function
2WD, Ride Control
Quick coupler, EH Clam, Radio Key ON
SAHR brake
Comfort Steer
PowerLift
Side lights
Customer B+
Customer key ON
Relay icon definitions

Symbol Function
Power relay #1
Power relay #2
SAHR park brake relay
SAHR park brake transmission cutout relay
Forward relay (Power Shuttle only)
A/C relay
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INTRODUCTION
Symbol Function
Comfort Steer relay (Power Shuttle only)
Reverse relay (Power Shuttle only)
Neutral relay
Starter interlock relay
Auto Ride Control relay
Rear light relay
PowerLift relay
Diode icon definitions

Symbol Function
Quick coupler diode #1
Reverse signal diode (Power Shuttle only)
Forward signal diode (Power Shuttle only)
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INTRODUCTION
Symbol Function
Torque control diode
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INTRODUCTION
Left-hand side steering column console panel

Power Shuttle Powershift
RCPH11TLB014AAD 3 RCPH11TLB015AAD 4
Fuse icon definitions

Symbol Function
Head lights
Front work lights
Turn signal, Hazards
Front wiper/washer
High beam
Beacon
Relay icon definitions

Symbol Function
Comfort steer relay and Power relay #1 (Power Shuttle
only)
Comfort steer relay and Power relay #2 (Power Shuttle

only)
Transmission De-clutch relay (Powershift only)
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INTRODUCTION
Symbol Function
Transmission lock relay (Powershift only)
Power relay #3
Power relay #4
Start relay
Diode icon definitions

Symbol Function
Reverse Signal Diode (Power Shuttle only)
Forward Signal Diode (Power Shuttle only)
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INTRODUCTION
Basic instructions - Diagnostic service tool port

580N, 580N NA, 580SN, 580SN NA, 580SN WT, 580SN WT NA, 590SN, 590SN NA
The diagnostic/service tool port is located in the fuse box at the side console. Connect the Electronic Service Tool
(EST) or DATAR to this port to update software and/or perform service and diagnostic tests.
1. Turn the thumb screws (1) to loosen the panel cover
RCPH10TLB437AAF 1
2. Unscrew the cap for the diagnostic/service tool port.

NOTE: You do not have to remove the fuse box
covers.
RCPH10TLB302AAF 2
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INTRODUCTION
Basic instructions - Welding on the machine

Contact your dealer if you have any questions before welding on this machine. The following procedures must be
completed before welding.
Remove the battery cover and disconnect the batteries.
RCPH10TLB429AAF 1
Disconnect the alternator terminal wires.
RCPH11TLB005BAD 2
Disconnect the engine control unit (ECU)

1. Remove the cover from the steering column shroud.
RCPH11TLB012BAD 3
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INTRODUCTION
2. Remove the ECU guard plate.
RCPH11TLB009BAD 4
3. Disconnect both connectors.
RCPH11TLB054BAD 5
Disconnect the instrument cluster.

1. Remove the instrument cluster panel.
2. Disconnect all connectors from the back of the
panel.
RCPH10TLB339AAF 6
• Disconnect the controller for backhoe pilot controls,

if equipped (one connector).
• Disconnect the transmission controller, if equipped
(one connector, located under the front steering
cowling).
• Disconnect the controller for the loader 4 in 1 bucket
or auxiliary hydraulics, if equipped (one connector,
located under the loader valve at the rear, left un-
derside of the machine).
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INTRODUCTION
Cab heater - Basic instructions

The heater coolant shutoff valve controls the flow of hot

coolant to the heater.
• In warm ambient temperatures, turn the shutoff

valve clockwise to stop hot coolant flow to the
heater.
• In cold ambient temperatures, turn the shutoff valve
counter-clockwise to allow hot coolant to flow to the
heater.
RCPH10TLB159AAF 1
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INTRODUCTION
Basic instructions
WARNING
Crushing hazard!
If you service the machine with the loader lift arms raised, always use the support strut. Remove the
retaining pin and place the support strut onto the cylinder rod. Install the retaining pin into the support
strut. Lower the lift arms onto the support strut.
W0230A
Raise and support loader lift arms:

1. Empty the loader bucket.
2. Raise the loader lift arms to the maximum height.
RCPH10TLB230AAF 1
4. Remove the retaining pin.

5. Lower the support strut onto the cylinder rod.
6. Install the retaining pin.
RCPH10TLB221AAF 2
7. Start the engine.

8. Slowly lower the lift arms so that the end of the sup-
port strut rests on the cylinder.
RCPH10TLB227AAF 3
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INTRODUCTION
Lower supported loader lift arms:

1. Raise the lift arms so that the end of the support strut
no longer rests on the cylinder.
RCPH10TLB227AAF 4
3. Remove the retaining pin from the support strut.

4. Raise the support strut up to the storage position
and secure with the retaining pin, as shown.
RCPH10TLB231AAF 5

6. Lower the loader to the ground.
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INTRODUCTION
Torque - Minimum tightening torques for normal assembly

METRIC NON-FLANGED HARDWARE

NOM. LOCKNUT LOCKNUT
SIZE CL.8 CL.10
CLASS 8.8 BOLT and CLASS 10.9 BOLT and W/CL8.8 W/CL10.9
CLASS 8 NUT CLASS 10 NUT BOLT BOLT
PLATED PLATED
UNPLATED UNPLATED
W/ZnCr W/ZnCr
2.2 N·m (19 lb 2.9 N·m (26 lb 3.2 N·m (28 lb 4.2 N·m (37 lb 2.9 N·m (26 lb
M4 2 N·m (18 lb in)
in) in) in) in) in)
4.5 N·m (40 lb 5.9 N·m (52 lb 6.4 N·m (57 lb 8.5 N·m (75 lb 5.8 N·m (51 lb
M5 4 N·m (36 lb in)
in) in) in) in) in)
7.5 N·m (66 lb 10 N·m (89 lb 11 N·m (96 lb 15 N·m (128 lb 6.8 N·m (60 lb 10 N·m (89 lb
M6
in) in) in) in) in) in)
18 N·m (163 lb 25 N·m (217 lb 26 N·m (234 lb 35 N·m (311 lb 17 N·m (151 lb 24 N·m (212 lb
M8
49 N·m (36 lb 70 N·m (51 lb 33 N·m (25 lb 48 N·m (35 lb
M10 37 N·m (27 lb ft) 52 N·m (38 lb ft)
ft) ft) ft) ft)
M12 64 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft) ft)
158 N·m (116 lb 210 N·m (155 225 N·m (166 lb 301 N·m (222 143 N·m (106 lb 205 N·m (151 lb
M16
ft) lb ft) ft) lb ft) ft) ft)
M20
M24
NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque
specifications are shown in pound-feet.
47365539 08/07/2012
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INTRODUCTION
METRIC FLANGED HARDWARE

NOM. CLASS 8.8 BOLT and CLASS 10.9 BOLT and LOCKNUT LOCKNUT
SIZE CLASS 8 NUT CLASS 10 NUT CL.8 CL.10
W/CL8.8 W/CL10.9
BOLT BOLT
PLATED PLATED
UNPLATED UNPLATED
W/ZnCr W/ZnCr
2.4 N·m (21 lb 3.2 N·m (28 lb 3.5 N·m (31 lb 4.6 N·m (41 lb 2.2 N·m (19 lb 3.1 N·m (27 lb
M4
4.9 N·m (43 lb 6.5 N·m (58 lb 7.0 N·m (62 lb 9.4 N·m (83 lb 4.4 N·m (39 lb 6.4 N·m (57 lb
M5
8.3 N·m (73 lb 11 N·m (96 lb 12 N·m (105 lb 16 N·m (141 lb 7.5 N·m (66 lb 11 N·m (96 lb
M6
M8
54 N·m (40 lb 77 N·m (56 lb
M10 40 N·m (30 lb ft) 57 N·m (42 lb ft) 37 N·m (27 lb ft) 53 N·m (39 lb ft)
ft) ft)
93 N·m (69 lb 100 N·m (74 lb 134 N·m (98 lb
M12 70 N·m (52 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft)
ft) ft) ft)
M16
M20
607 N·m (447 lb 809 N·m (597 838 N·m (618 lb 1118 N·m (824 552 N·m (407 lb
M24
ft) lb ft) ft) lb ft) ft)
IDENTIFICATION
Metric Hex head and carriage bolts, classes 5.6 and up
20083680 1
1. Manufacturer's Identification
2. Property Class
Metric Hex nuts and locknuts, classes 05 and up
20083681 2
47365539 08/07/2012
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INTRODUCTION
1. Manufacturer's Identification
2. Property Class
3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60 ° apart indicate
Class 10 properties, and marks 120 ° apart indicate Class 8.
INCH NON-FLANGED HARDWARE

LOCKNUT LOCKNUT
NOMINAL SAE GRADE 5 BOLT SAE GRADE 8 BOLT
GrB W/ Gr5 GrC W/ Gr8
SIZE and NUT and NUT
BOLT BOLT
UN-
UN-
PLATED PLATED PLATED
PLATED
or W/ZnCr W/ZnCr
or PLATED
PLATED GOLD GOLD
SILVER
SILVER
8 N·m (71 lb 11 N·m (97 lb 12 N·m (106 16 N·m (142 12.2 N·m (109 lb
1/4 8.5 N·m (75 lb in)
in) in) lb in) lb in) in)
17 N·m (150 23 N·m (204 24 N·m (212 32 N·m (283 17.5 N·m (155 lb 25 N·m (220 lb
5/16
lb in) lb in) lb in) lb in) in) in)
30 N·m (22 lb 40 N·m (30 43 N·m (31 lb 57 N·m (42 lb
3/8 31 N·m (23 lb ft) 44 N·m (33 lb ft)
ft) lb ft) ft) ft)
48 N·m (36 lb 65 N·m (48 68 N·m (50 lb 91 N·m (67 lb
7/16 50 N·m (37 lb ft) 71 N·m (53 lb ft)
ft) lb ft) ft) ft)
74 N·m (54 lb 98 N·m (73 104 N·m (77 139 N·m (103
1/2 76 N·m (56 lb ft) 108 N·m (80 lb ft)
ft) lb ft) lb ft) lb ft)
107 N·m (79 142 N·m (105 150 N·m (111 201 N·m (148 156 N·m (115 lb
9/16 111 N·m (82 lb ft)
lb ft) lb ft) lb ft) lb ft) ft)
147 N·m (108 196 N·m (145 208 N·m (153 277 N·m (204 153 N·m (113 lb 215 N·m (159 lb
5/8
lb ft) lb ft) lb ft) lb ft) ft) ft)
3/4
7/8
630 N·m (465 841 N·m (620 890 N·m (656 1187 N·m 654 N·m (483 lb 924 N·m (681 lb
1
lb ft) lb ft) lb ft) (875 lb ft) ft) ft)
NOTE: For Imperial Units, 1/4 in and 5/16 in hardware torque specifications are shown in pound-inches. 3/8 in
through 1 in hardware torque specifications are shown in pound-feet.
47365539 08/07/2012
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INTRODUCTION
INCH FLANGED HARDWARE

NOM- LOCKNUT LOCKNUT
SAE GRADE 5 BOLT and SAE GRADE 8 BOLT and
INAL GrF W/ Gr5 GrG W/ Gr8
NUT NUT
SIZE BOLT BOLT
UNPLATED PLATED UNPLATED PLATED
or PLATED W/ZnCr or PLATED W/ZnCr
SILVER GOLD SILVER GOLD
1/4 9 N·m (80 lb in) 8 N·m (71 lb in)
in) in) in) in)
5/16
44 N·m (33 lb 47 N·m (35 lb 63 N·m (46 lb
3/8 33 N·m (25 lb ft) 30 N·m (22 lb ft) 43 N·m (32 lb ft)
ft) ft) ft)
71 N·m (52 lb 75 N·m (55 lb 100 N·m (74 lb
7/16 53 N·m (39 lb ft) 48 N·m (35 lb ft) 68 N·m (50 lb ft)
ft) ft) ft)
108 N·m (80 lb 115 N·m (85 lb 153 N·m (113 104 N·m (77 lb
1/2 81 N·m (60 lb ft) 74 N·m (55 lb ft)
ft) ft) lb ft) ft)
117 N·m (86 lb 156 N·m (115 165 N·m (122 221 N·m (163 157 N·m (116 lb
9/16 106 N·m (78 lb ft)
ft) lb ft) lb ft) lb ft) ft)
162 N·m (119 lb 216 N·m (159 228 N·m (168 304 N·m (225 147 N·m (108 lb 207 N·m (153 lb
5/8
ft) lb ft) lb ft) lb ft) ft) ft)
3/4
7/8
1
IDENTIFICATION
Inch Bolts and free-spinning nuts
20083682 3
Grade Marking Examples
SAE Grade Identification

1 Grade 2 - No Marks 4 Grade 2 Nut - No Marks
2 Grade 5 - Three Marks 5 Grade 5 Nut - Marks 120 ° Apart
3 Grade 8 - Five Marks 6 Grade 8 Nut - Marks 60 ° Apart
47365539 08/07/2012
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INTRODUCTION
Inch Lock Nuts, All Metal (Three optional methods)
20090268 4
Grade Identification
Grade Corner Marking Method (1) Flats Marking Method (2) Clock Marking Method (3)
Grade A No Notches No Mark No Marks
Grade B One Circumferential Notch Letter B Three Marks
Grade C Two Circumferential Notches Letter C Six Marks
47365539 08/07/2012
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INTRODUCTION
Torque - Standard torque data for hydraulics

INSTALLATION OF ADJUSTABLE FITTINGS

IN STRAIGHT THREAD O RING BOSSES
1. Lubricate the O-ring by coating it with a light oil or

petroleum. Install the O-ring in the groove adjacent
to the metal backup washer which is assembled at
the extreme end of the groove (4).
2. Install the fitting into the SAE straight thread boss
until the metal backup washer contacts the face of
the boss (5).
NOTE: Do not over tighten and distort the metal
backup washer. 23085659 1
3. Position the fitting by turning out (counterclockwise)
up to a maximum of one turn. Holding the pad of the
fitting with a wrench, tighten the locknut and washer
against the face of the boss (6).
STANDARD TORQUE DATA FOR HYDRAULIC TUBES AND FITTINGS

TUBE NUTS FOR 37° FLARED FITTINGS O-RING BOSS PLUGS
ADJUSTABLE FITTING
LOCKNUTS, SWIVEL
JIC- 37° SEATS
SIZE TUBING OD THREAD TORQUE TORQUE
SIZE
4 6.4 mm (1/4 in) 7/16-20 12 - 16 N·m (9 - 12 lb ft) 8 - 14 N·m (6 - 10 lb ft)
12 19.1 mm (3/4 in) 1-1/16-12 104 - 111 N·m (77 - 82 lb ft) 81 - 95 N·m (60 - 70 lb ft)
14 22.2 mm (7/8 in) 1-3/16-12 122 - 136 N·m (90 - 100 lb ft) 95 - 109 N·m (70 - 80 lb ft)
16 25.4 mm (1 in) 1-5/16-12 149 - 163 N·m (110 - 120 lb ft) 108 - 122 N·m (80 - 90 lb ft)
20 31.8 mm (1-1/4 in) 1-5/8-12 190 - 204 N·m (140 - 150 lb ft) 129 - 158 N·m (95 - 115 lb ft)
24 38.1 mm (1-1/2 in) 1-7/8-12 217 - 237 N·m (160 - 175 lb ft) 163 - 190 N·m (120 - 140 lb ft)
32 50.8 mm (2 in) 2-1/2-12 305 - 325 N·m (225 - 240 lb ft) 339 - 407 N·m (250 - 300 lb ft)
These torques are not recommended for tubes of 12.7 mm (1/2 in) OD and larger with wall thickness of 0.889 mm
(0.035 in) or less. The torque is specified for 0.889 mm (0.035 in) wall tubes on each application individually.
Before installing and torquing 37 ° flared fittings, clean the face of the flare and threads with a clean solvent or Loctite
cleaner and apply hydraulic sealant LOCTITE® 569 to the 37 ° flare and the threads.
Install fitting and torque to specified torque, loosen fitting and retorque to specifications.
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INTRODUCTION
PIPE THREAD FITTING TORQUE PIPE THREAD FITTING

Thread Size Torque (Maximum)
Before installing and tightening pipe fittings, clean the
threads with a clean solvent or Loctite cleaner and apply 1/8-27 13 N·m (10 lb ft)
sealant LOCTITE® 567 PST PIPE SEALANT for all fittings 1/4-18 16 N·m (12 lb ft)
including stainless steel or LOCTITE® 565 PST for most 3/8-18 22 N·m (16 lb ft)
metal fittings. For high filtration/zero contamination sys- 1/2-14 41 N·m (30 lb ft)
tems use LOCTITE® 545. 3/4-14 54 N·m (40 lb ft)
INSTALLATION OF ORFS (O-RING FLAT

FACED) FITTINGS
When installing ORFS fittings thoroughly clean both flat
surfaces of the fittings (1) and lubricate the O-ring (2) with
light oil. Make sure both surfaces are aligned properly.
Torque the fitting to specified torque listed throughout the
repair manual.
NOTICE: If the fitting surfaces are not properly cleaned,
the O-ring will not seal properly. If the fitting surfaces are
not properly aligned, the fittings may be damaged and will
not seal properly.
NOTICE: Always use genuine factory replacement oils
50011183 2
and filters to ensure proper lubrication and filtration of en-
gine and hydraulic system oils.
The use of proper oils, grease, and keeping the hydraulic

system clean will extend machine and component life.
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INTRODUCTION
Abbreviation Measurements
Typical applications Metric unit Imperial unit

Name Symbol Name Symbol
Area (Land area)

hectare ha acre ac
square meter m² square foot ft²
square inch in²
square millimeter mm² square inch in²
Electricity
ampere A ampere A
volt V volt V
microfarad µF microfarad µF
ohm Ω ohm Ω
Force
kilonewton kN pound lb
newton N pound lb
Force per length
newton per meter N/m pound per foot lb/ft
pound per inch lb/in
Frequency
megahertz MHz megahertz MHz
kilohertz kHz kilohertz kHz
hertz Hz hertz Hz
Frequency − Rotational
revolution per minute r/min revolution per minute r/min ª
rpm rpm
Length
kilometer km mile mi
meter m foot ft
centimeter cm inch in
millimeter mm inch in
micrometer µm
Mass
kilogram kg pound lb
gram g ounce oz
milligram mg
Power
kilowatt kW horsepower Hp
watt W Btu per hour Btu/hr
Btu per minute Btu/min
Pressure or stress (Force per area)
kilopascal kPa pound per square inch psi
inch of mercury inHg
pascal Pa inch of water inH2O
megapascal MPa pound per square inch psi
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INTRODUCTION
Typical applications Metric unit Imperial unit

Name Symbol Name Symbol
Temperature (other than Thermodynamic)

degrees Celsius °C degrees Fahrenheit °F
Time
hour h hour h
minute min minute min
second s second s
Torque (includes Bending moment, Moment of force, and Moment of a couple)
newton meter Nm pound foot lb ft
pound foot lb in
Velocity
kilometer per hour km/h mile per hour mph
meter per second m/s foot per second ft/s
millimeter per second mm/s inch per second in/s
meter per minute m/min foot per minute ft/min
Volume (includes Capacity)
cubic meter mm³ cubic yard yd³
cu yd
liter l cubic inch in³
liter l US gallon US gal
UK gallon UK gal
US quart US qt
UK quart UK qt
milliliter ml fluid ounce fl oz
Volume per time (includes Discharge and Flow rate)
cubic meter per m³/min cubic foot per minute ft³/min
minute
liter per minute l/min US gallon per minute US gal/min
milliliter per minute ml/min UK gallon per minute UK gal/min
Sound power level and Sound pressure level
decibel dB decibel dB
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INTRODUCTION
Capacities
Engine crank case

Specification: TUTELA UNITEK CJ-4 ENGINE OIL SAE 10W-40( API CJ-4)
Capacity:
With filter change 8.00 l (8.45 US qt)
Fuel tank
Specification: No. 2 diesel
Capacity: 159.0 l (42.0 US gal)
Cooling system
Specification: CNH XHD PREMIX ( 50 % water and 50 % ethylene glycol)
Capacity:
580N
Without heater 16.1 l (17.0 US qt)
With heater 16.8 l (17.8 US qt)
580SN, 580SN-WT, 590SN

Without heater 17.3 l (18.3 US qt)
With heater 18.0 l (19.0 US qt)
Hydraulic system
Specification: CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL
Capacity:
580N
Total system 106.0 l (112.0 US qt)
Total system with Extendahoe 111.7 l (118.0 US qt)
Reservoir with filter change 55.0 l (58.1 US qt)
Reservoir without filter change 53.0 l (56.0 US qt)
580SN
580SN-WT
590SN
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INTRODUCTION
Transmission
Specification: CASE AKCELA HY-TRAN® ULTRA™ HYDRAULIC TRANSMISSION OIL
Capacity:
Manual (powershuttle)
Two wheel drive Four wheel drive
Total system 17.0 l (18 US qt) 19.4 l (21 US qt)
Refill (with or without filter change) 10.5 l (11 US qt) 13.0 l (14 US qt)
Powershift S-type
Two wheel drive Four wheel drive
Total system 21.7 l (22.9 US qt) 20.7 l (21.9 US qt)
Refill (with or without filter change) 15.3 l (16.2 US qt) 14.3 l (15.1 US qt)
Powershift H-type
Four wheel drive only
Refill (with or without filter change) 11.4 l (12.0 US qt)
Front drive axle - Two wheel drive

Specification: TUTELA TRANSAXLE FLUID SAE 80W-140
Capacity:
Each hub 0.8 l (0.8 US qt)
Front drive axle - Four wheel drive

Capacity:
580N, 580SN
Differential 7.7 l (8.1 US qt)
Each planetary hub 0.5 l (0.5 US qt)
580SN-WT, 590SN
Differential 8.6 l (9.1 US qt)
Each planetary hub 1.0 l (1.1 US qt)
Rear axle (differential)

Capacity:
580N, 580SN 13.6 l (14.4 US qt)
580SN-WT, 590SN 18.6 l (19.7 US qt)
Brake master cylinder

Brake fluid supplied by the transmission.
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INTRODUCTION
Consumables
CJ-4 Oils – Tier 4 F5C emissions equipped machines

Recommended operating temperature range
(H) 0W-40 CJ-4 UNITEK to MAT3521
(H) API CJ–4 0W-40
(H) 10W-40 CJ-4 UNITEK to CNH MAT3521
(H) API CJ–4 10W-40
(H) 15W-40 CJ-4 UNITEK to CNH MAT3521
(H) API CJ–4 15W-40
-40 °C -30 °C -20 °C -10 °C 0 °C 10 °C 20 °C 30 °C 40 °C 50 °C

-40 °F -22 °F -4 °F 14 °F 32 °F 50 °F 68 °F 86 °F 104 °F 122 °F
(H) Engine oil pan or coolant block heater recommended in this range
Dye and black light procedure for detecting oil leaks

Oils and grease have natural phosphors and will illuminate differently under the black light. Oil, bluish-white, grease,
brilliant-white, anti-freeze, greenish-yellow, sealing compounds, red to orange.
Kit part number 380040182 consisting of:

Part Number Description Unit of Comments Usage
measurement
12 Volt Ultra Violet
380002254 Black Light — —
Light
Glows Green in Black Engine Oil /
380002357 Dye-uniglow F2HF 10 ml (0.34 US fl oz)
Light Crankcase
Glows Yellow in Black
380002358 Dye-uniglow F4HF 65 ml (2.2 US fl oz) Hydraulic Oil
Light
Glows Purple in Black
380002359 Dye-uniglow 1750 10 ml (0.34 US fl oz) Transmission Oil
Light
NOTE: Each dye is formulated to work in conjunction with a specific fluid, therefore the dyes are not interchangeable
and should only be used as described.
47365539 08/07/2012
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INTRODUCTION
1. Prior to adding dye, connect the black light to the

machines battery and investigate suspected areas.
2. Once suspected leak areas are found, attempt to
trace the leak completely to the origin.
NOTE: At the origin, the leak should be the brightest
in color.
3. After confirmation of the suspected leak, thoroughly
clean the area of the leak to remove any existing flu-
ids. Recheck the area with the black light to assure
the area is clean. Good cleaning is important for the
following reasons:
• Fluids captured by threaded joints or other
cavities will continue to show signs of leakage
unless completely clean. RCPH10TLB245ACL 1
• Casting surfaces can hold residual oil.

4. Use the entire contents of the bottle of dye in the
system/systems of the suspected leak.
5. Run the unit for 5 to 10 minutes and cycle through
suspect system functions to ensure that the dye is
available to all possible leak points.
NOTE: The hydraulic oil should be heated to 71 °C
(160 °F), engine at normal operating temperature,
and transmission should be in the normal operating
range on the gauge.
6. Use a clean cloth and wipe the dipstick or the inside
surface of the filler tube on each of the 3 sumps.
7. View traces of dyed fluid on the cloth under the black
light to ensure good samples.
8. Use these 3 samples as your baseline when inspect-
ing the unit with the black light.
NOTE: High hour engine oil can reduce the effec-
tiveness of the dye. In this event change the oil.
9. Avoid common errors.
• Fan airflow blowing leaking fluid.
• Gravity pulling leak paths down.
• When paint at a joint is not broken, the joint is
not leaking.
NOTE: It is not necessary to change oils after this
check.
47365539 08/07/2012
38
INTRODUCTION
Diesel fuel
Use No. 2 diesel fuel in the engine of this machine. The Specifications for acceptable No. 2 Diesel Fuel
use of other fuels can cause the loss of engine power and API gravity (minimum) 34
high fuel consumption.
Flash point (minimum) 60 °C (140 °F)
In very cold temperatures, a mixture of No. 1 and No. 2 * Cloud point (maximum) -20 °C (-4 °F)
diesel fuels is temporarily permitted. * Pour point (maximum) -26 °C (-15 °F)
Viscosity (at) 88 °C (190 °F)
NOTICE: See your fuel dealer for winter fuel requirements
Centistokes (2.0) to (4.3)
in your area. If the temperature of the fuel is below the
cloud point (wax appearance point), wax crystals in the Saybolt Seconds Universal (32) to (40)
fuel will cause the engine to lose power or not start. * Refer to the Notice on this page.
The diesel fuel used in this machine must meet the specifi-
cations in the chart or Specification D975-81 of the Amer-
ican Society for Testing and Materials.
Fuel Storage
If you keep fuel in storage for a period of time, you can get
foreign material or water in the fuel storage tank. Many
engine problems are caused by water in the fuel.
Keep the fuel storage tank outside and keep the fuel as
cool as possible. Remove water from the storage con-
tainer at regular periods of time.
47365539 08/07/2012
39
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 569 Torque - Standard torque data for hydraulics 31
Loctite® 567 PST Pipe Torque - Standard torque data for hydraulics 32
Sealant
Loctite® 565 PST Torque - Standard torque data for hydraulics 32
Loctite® 545 Torque - Standard torque data for hydraulics 32
Tutela Unitek CJ-4 engine oil Capacities 35
SAE 10W-40
CNH XHD Premix Capacities 35
CASE Akcela HY-TRAN® Capacities 35
Ultra™ hydraulic transmission
oil
CASE Akcela HY-TRAN® Capacities 36
Ultra™ hydraulic transmission
oil
Tutela Transaxle fluid SAE Capacities 36
80W-140
80W-140
80W-140
47365539 08/07/2012
40
SERVICE MANUAL
Engine
580N
580SN WT
580SN
590SN
47365539 08/07/2012
10
Contents
Engine - 10
Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001

580N , 580SN WT , 580SN , 590SN
Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.216

580N , 580SN WT , 580SN , 590SN
Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400

580N , 580SN WT , 580SN , 590SN
Exhaust Gas Recirculation (EGR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.501

580N , 580SN WT , 580SN , 590SN
47365539 08/07/2012
10
Engine - 10
Engine and crankcase - 001
580N
580SN WT
580SN
590SN
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Contents
Engine - 10
TECHNICAL DATA
Engine
General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Speeds stall test normal (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Speeds stall test check sheet (580N only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

580N NA T4
Speeds stall test check sheet (580SN only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

580SN NA T4
Speeds stall test check sheet (590SN only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

590SN NA T4
Speeds stall test check sheet (580SN WT only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

580SN WT NA T4
FUNCTIONAL DATA
Engine
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE
Engine
Service instruction - Engine repair service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Prepare for stall tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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Engine - Engine and crankcase
Engine - General specification

Model 580N
Model Diesel, F5HFL413D*A
Type Four cylinder, turbocharged
Firing order 1-3-4-2
Bore and stroke 99mm x 110mm (3.9 in x 4.33 in)
Displacement 3.4 l (207 in³)
Compression ratio 16.5 to 1
Fuel injection Direct HPCR
Horsepower - rated at 2200 RPM
Gross 63 kW (85 Hp)
Net with 39 ° fan 58 kW (79 Hp)
Peak torque at 1400 RPM
Gross 374 N·m (276 lb ft)
Net with 39 ° fan 364 N·m (268 lb ft)
Maximum torque rise 36% ± 5 RPM
Model 580SN and 580SN-WT

Model Diesel, F5HFL413C*A
Gross 72 kW (97 Hp)
Model 590SN
Model Diesel, F5HFL413B*A
Gross 82 kW (110 Hp)
Engine - Speeds stall test normal (all models)

NOTE: The following specifications are for engines with more than 50 hours of operation.
47365539 08/07/2012
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NOTE: Engine RPM speed is based on the ISO14396 Cetane number of at least 51 and density between 820 - 845
kg/m³ (1382 - 1424 lb/yd³). Fuel inlet 38 °C (100 °F) ± 2 °C (36 °F)
Model 580N
Function Engine RPM speed
Rated speed – full load 2200 RPM
Low idle 900 - 1000 RPM
High idle– no load 2330 - 2430 RPM
Torque converter stall 2180 - 2310 RPM
Backhoe hydraulic stall 2230 - 2330 RPM
Loader hydraulic stall 2230 - 2330 RPM
Combined stall 1610 - 1890 RPM
Model 580SN
Model 590SN
Model 580SN WT
Engine - Speeds stall test check sheet (580N only)

580N NA T4
Results from stall test procedure (fill in values accordingly)

ID RPM test valve Stall test component (specified value)
1 Loader hydraulic stall speed ( 2230 - 2330 RPM)
2 Backhoe hydraulic stall speed ( 2230 - 2330 RPM)
3 Torque converter stall speed ( 2180 - 2310 RPM)
4 Combined - loader hydraulic and torque converter - stall speed ( 1610 - 1890 RPM)
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Stall test reference chart

ID RPM Results
1 2230 to 2330
2 2230 to 2330
All systems operating within normal specified RPM values.
3 2180 to 2310
4 1610 to 1890
1 Above 2330
2 2230 to 2330
Engine problem. Check engine speeds. Refer to the engine service manual.
3 Above 2310
4 Above 1890
1 Below 2230
2 2230 to 2330 Engine problem. Check engine speeds. Replace the fuel and air filters. Refer
3 Below 2180 to the engine service manual.
4 Below 1610
1 Below 2230
2 2230 to 2330 Hydraulic system problem(s). Check the setting of the main relief valve. Check the
3 2180 to 2310 output of the hydraulic pump.
4 Below 1610
1 Above 2330
3 2180 to 2310 output of the hydraulic pump. Check for leakage in the loader control valve.
4 Above 1890
1 2230 to 2330
2 Below 2230 Hydraulic system problem(s). Check the setting of the main relief valve. Check the
4 1610 to 1890
1 2230 to 2330
4 1610 to 1890
1 2230 to 2330
2 2230 to 2330
Torque converter or transmission problems.
3 Above 2310
4 Above 1890
1 2230 to 2330
2 2230 to 2330
3 Below 2180
4 Below 1610
Engine - Speeds stall test check sheet (580SN only)

580SN NA T4


ID RPM Results
1 2240 to 2335
2 2160 to 2300
3 2080 to 2260
4 1695 to 1930
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ID RPM Results
1 Above 2335
2 2160 to 2300
Engine problem. Check engine speeds. Refer to the engine service manual.
3 Above 2260
4 Above 1930
1 Below 2240
2 2160 to 2300 Engine problem. Check engine speeds. Replace the fuel and air filters Refer
4 Below 1695
1 Below 2240
4 Below 1695
1 Above 2335
4 Above 1930
1 2240 to 2335
4 1695 to 1930
1 2240 to 2335
4 1695 to 1930
1 2240 to 2335
2 2160 to 2300
3 Above 2260
4 Above 1930
1 2240 to 2335
2 2160 to 2300
3 Below 2080
4 Below 1695
Engine - Speeds stall test check sheet (590SN only)

590SN NA T4


ID RPM Results
1 2240 to 2335
2 2190 to 2300
3 2125 to 2290
4 1830 to 2010
1 Above 2335
2 2190 to 2300 Engine problem. Check engine speeds according to instructions in the engine
3 Above 2290 service manual.
4 Above 2010
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ID RPM Results
1 Below 2240
2 2190 to 2300 Engine problem. Check engine speeds according to instructions in Refer to the
3 Below 2125 engine service manual.
4 Below 1830
1 Below 2240
4 Below 1830
1 Above 2335
4 Above 2010
1 2240 to 2335
4 1830 to 2010
1 2240 to 2335
4 1830 to 2010
1 2240 to 2335
2 2190 to 2300 Torque converter or transmission problems. Refer to section NEED IU
3 Above 2290 REFERENCE and check the transmission and torque converter.
4 Above 2010
1 2240 to 2335
2 2190 to 2300
3 Below 2125
4 Below 1830
Engine - Speeds stall test check sheet (580SN WT only)

580SN WT NA T4


ID RPM Results
1 2330 to 2420
2 2330 to 2420
3 2150 to 2295
4 2090 to 2270
1 Above 2420
2 2330 to 2420
Engine problem. Check engine speeds according to the engine service manual.
3 Above 2295
4 Above 2270
1 Below 2330
2 2330 to 2420 Engine problem. Check engine speeds. Replace the fuel and air filters. Refer
4 Below 2090
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ID RPM Results
1 Below 2330
4 Below 2090
1 Above 2420
4 Above 2270
1 2330 to 2420
4 2090 to 2270
1 2330 to 2420
4 2090 to 2270
1 2330 to 2420
2 2330 to 2420
3 Above 2295
4 Above 2270
1 2330 to 2420
2 2330 to 2420
3 Below 2150
4 Below 2090
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Engine - Exploded view

1. Engine mounting bracket bolt 4. Engine mounting bracket

2. Flat washer 5. Engine mounting stabilizer
3. Engine mounting bolts 6. Lock nut
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RCPH11TLB006HAL 1
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Engine - Service instruction - Engine repair service manual

1. For engine repair, see engine service manual

84496807.
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Engine - Prepare for stall tests

Do the stall test to find the cause of poor performance.

The main relief valve must be set within specifications to achieve accurate readings when performing the following
stall tests.
The engine is run at full throttle and the transmission and hydraulic systems are engaged separately, and then to-
gether.
Comparing the engine speeds from the stall test with the check sheets in this section will help to find the cause of the
problem. It can be necessary to check a separate system to find the exact cause of the problem.
Use a photo tachometer or other tachometer of equal accuracy to get accurate results from the stall test.
The engine, transmission and hydraulic system must be at operating temperature before doing the stall test. Heat the
oil according to instructions in this section.
Machines with standard transmission

NOTE: For 580N machines only and check the throttle linkage adjustments.
1. Apply the parking brake.
2. Move the transmission gear selector into fourth gear.
3. Lock the brake pedals together. Put your foot on
the service brakes and hold the machine with service
brakes.
4. Release the parking brake.
5. With the engine running at low idle, move the direc-
tion control lever forward.
6. Slowly increase the engine speed to full throttle.
7. If the machine begins to move at any time, decrease
the engine speed to low idle and stop the engine.
Machines with H–Type transmission

2. Place the automatic/manual switch in the manual po-
sition.
3. Select 4th gear on the range selector.
brakes.
6. With the engine running at low idle, move the direc-
tion control lever forward.
7. Slowly increase the engine speed to full throttle.
8. If the machine begins to move at any time, decrease
the engine speed to low idle and stop the engine.
Refer to sections Parking brake disks - Inspect
(33.110), Parking brake disks - Test (33.110) and
Parking brake disks - Check (33.110).
Procedure to heat torque converter and hydraulic oil

2. Start and run the engine at low idle.
47365539 08/07/2012
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3. Run the engine at full throttle, hold the loader control

lever in the rollback position for 15 seconds.
4. Return the loader control lever to neutral for 15 sec-
onds.
5. Return the boom control lever to neutral for 15 sec-
onds.
6. Repeat steps 3 and 4 until the temperature of the oil
is 52 °C (126 °F). The side of the reservoir will be
very warm at this temperature.
7. With the engine running at low idle, move the trans-
mission control to fourth gear and the direction con-
trol lever to forward.
8. Run the engine at full throttle for 15 seconds.
9. Decrease the engine speed to low idle and move the
direction control lever to neutral for 15 seconds.
10. Repeat steps 6 through 8 until the pointer in the
gauge for transmission oil temperature is in the cen-
ter of the green zone of the gauge for transmission
oil temperature.
Stall test procedure

1. Prepare the machine for the stall test according to
instructions in this section.
2. Heat the oil according to instructions in this section.
3. Apply the parking brake and start the engine.
4. With the engine running at full throttle, hold the loader
control lever in the lift position and read the tachome-
ter. Record the reading on line 1 of the check sheet.
5. With the engine running at full throttle and boom in
travel lock, hold the dipper lever in the in position and
read the tachometer. Record the reading on line 2 of
the check sheet.
6. Decrease the engine speed to low idle.
7. Move the transmission control lever to fourth gear.
NOTE: For machines with H-Type transmissions, place the
automatic/manual switch in the manual position.
brakes.
10. Move the direction control lever to forward.
11. Slowly increase the engine speed to full throttle and
read the tachometer. Record the reading on line 3
on the check sheet.
12. With the transmission control lever in fourth gear, the
direction control lever in forward, and the engine run-
ning at full throttle, hold the loader control lever in
the lift position and read the tachometer. Record the
reading on line 4 on the check sheet.
13. Decrease the engine speed to low idle, move the
directional control lever to neutral.
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14. Run the engine at low idle for two minutes and then
stop the engine.
15. See the check sheet to understand the results of the
stall test.
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Engine - Remove
Prior operation:
Drain the hydraulic tank.
Prior operation:
Disconnect the batteries.
Prior operation:
Engine hood - Remove (90.105)
1. Remove the air intake tube support bracket bolts (1)

and bracket (2).
RAPH11TLB0030BA 1
2. Disconnect the A/C condenser inlet line (1).

3. Disconnect the inlet fuel cooler line (2).
4. Disconnect the outlet fuel cooler line (3).
5. Disconnect the A/C condenser outlet line (4).
RAPH11TLB0037BA 2
6. Remove the horn bracket nut (1). Place the horn and
horn bracket away from the cooling package.
RAPH11TLB0035BA 3
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7. Loosen and remove the receiver/dryer hold-down

clamps (1). Place the receiver/dryer away from the
cooling package.
RAPH11TLB0036BA 4
8. Support the cooling package housing wrapper.
RAPH11TLB0038BA 5
9. Remove the cooling package housing wrapper bolts

(1), (2).
RAPH11TLB0029BA 6
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10. Carefully lift and remove the cooling package hous-

ing wrapper.
RAPH11TLB0038BA 7
11. Label and disconnect the hydraulic oil hoses (1) lead-
ing to the hydraulic oil cooler.
RAPH11TLB0034BA 8
12. Disconnect the air intake tube (1) from the air cleaner.
RAPH11TLB0031BA 9
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13. Disconnect the lower radiator hose (1) from the radi-
ator.
14. Label and disconnect the transmission oil cooler
hoses (2) leading to the transmission oil cooler.
RAPH11TLB0033BA 10
15. Disconnect the turbo outlet tube (1) at the turbo.

16. Disconnect the upper radiator hose (2) from the ra-
diator.
RAPH11TLB0032BA 11
17. Support the cooling package using safe, lifting equip-

ment.
RAPH11TLB0027BA 12
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18. Remove the hood strut post (2) and retainer (1) .
RAPH11TLB0028BA 13
19. Remove the cooling package retaining bolts (1).

Carefully lift and remove the cooling package.
RAPH11TLB0027BA 14
20. Disconnect the A/C high pressure line (1).

21. Disconnect electrical connectors (2) and (3).
22. Disconnect the A/C low pressure line (4).
23. Disconnect the A/C condenser voltage wire (5).
RAPH11TLB0045BA 15
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24. Disconnect fuel lines (1) and (2).
RAPH11TLB0041BA 16
25. Disconnect the water sensor electrical connector (not

shown).
NOTE: Water sensor is located at the bottom of the primary
fuel filter.
26. Remove the diesel particulate filter (DPF) system.
See Particulate filters - Remove (10.501)
27. Remove the DPF tray (1).
RAPH11TLB0022BA 17
28. Disconnect the glow plug control unit electrical con-

nector (1).
RAPH11TLB0021BA 18
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29. Remove the supporting bracket (1) and hanging bar-

rier curtain (2).
RAPH11TLB0040BA 19
30. Disconnect the heater hose (1).
RAPH11TLB0039BA 20
31. Label and disconnect the air sensor wires (1).
RAPH11TLB0044BA 21
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32. Label and disconnect the alternator electrical con-

nector (1) and the alternator battery wire (2).
RAPH11TLB0043BA 22
33. Remove the starter (1).
RAPH11TLB0042BA 23
34. Remove the button plug and the insert flywheel turn-
ing tool, part number 380000988.
RAPH11TLB0017BA 24
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35. Remove the cover. Turn the flywheel using the fly-
wheel turning tool to expose the flywheel bolts (1).
Remove the flywheel bolts (1).
RAPH11TLB0016BA 25
36. Support the engine using safe, lifting equipment.
RAPH11TLB0018BA 26
37. Removing the engine mounts (1).

NOTE: Lower radiator hose removed for picture clarity.
RAPH11TLB0019BA 27
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38. Remove the bell housing bolts (1).
RAPH11TLB0020BA 28
39. Carefully lift and remove the engine from the chassis.
RAPH11TLB0018BA 29
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Engine - Install
1. Carefully lower the engine into the chassis.
RAPH11TLB0018BA 1
2. Install the bell housing bolts (1). Tighten the bell

housing bolts (1) to a torque of 52 - 57 N·m (38 -
42 lb ft).
RAPH11TLB0020BA 2
3. Install the engine mounts (2). Tighten the mounting

bolts (1) to 212 - 241 N·m (156 - 178 lb ft).
NOTE: Lower radiator hose removed for picture clarity.
RAPH11TLB0019BA 3
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4. Remove the lifting equipment (1).
RAPH11TLB0018BA 4
5. Install the flywheel bolts (1). Tighten the flywheel

bolts to 30 N·m (22 lb ft)
RAPH11TLB0016BA 5
6. Install the bell housing flywheel bolt cover and button

plug.
7. Install the starter (1). Tighten starter bolts (2) to a
torque of 45 N·m (33 lb ft).
RAPH11TLB0042BA 6
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8. Connect the alternator electrical connector (1) and

the alternator battery wire (2).
RAPH11TLB0043BA 7
9. Connect the air sensor wires (1).
RAPH11TLB0044BA 8
10. Connect the heater hose (1).
RAPH11TLB0039BA 9
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11. Install the hanging barrier curtain (2) and the support-
ing bracket (1).
RAPH11TLB0040BA 10
12. Connect the glow plug control unit electrical connec-

tor (1).
RAPH11TLB0021BA 11
13. Install the diesel particulate filter (DPF) tray (1).
RAPH11TLB0022BA 12
14. Install the DPF system. See Particulate filters -

Install (10.501)
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15. Connect the water sensor electrical connector (not

shown).
NOTE: Water sensor is located at the bottom of the primary
fuel filter.
16. Connect fuel lines (1) and (2).
RAPH11TLB0041BA 13
17. Connect the A/C high pressure line (1).

18. Connect electrical connectors (2) and (3).
19. Connect the A/C low pressure line (4).
20. Connect the A/C condenser voltage wire (5).
RAPH11TLB0045BA 14
21. Carefully lower the cooling package onto the chas-

sis. Install the cooling package retaining bolts (2).
Remove the lifting equipment (1).
NOTICE: Cooling package fan shroud may come in contact
with engine fan blade. Verify engine fan blade has proper
clearance for rotation. Adjust cooling package as neces-
sary.
RAPH11TLB0027BA 15
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22. Install the hood strut post (2) and retainer (1) .
RAPH11TLB0028BA 16
23. Connect the turbo outlet tube (1) to the turbo.

24. Connect the upper radiator hose (2) to the radiator.
RAPH11TLB0032BA 17
25. Connect the lower radiator hose (1) to the radiator.

26. Connect the transmission oil cooler hoses (2) to the
transmission oil cooler.
RAPH11TLB0033BA 18
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27. Connect the air intake tube (1) to the air cleaner.
RAPH11TLB0031BA 19
28. Connect the hydraulic oil hoses (1) to the hydraulic

oil cooler.
RAPH11TLB0034BA 20
29. Lower the cooling package housing wrapper onto the

cooling package.
RAPH11TLB0038BA 21
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30. Install the cooling package housing wrapper bolts

(1), (2).
RAPH11TLB0029BA 22
31. Remove the lifting equipment (1).
RAPH11TLB0038BA 23
32. Install the receiver/dryer (1).
RAPH11TLB0036BA 24
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33. Connect the A/C condenser outlet line (4).

34. Connect the A/C condenser inlet line (1).
35. Connect the inlet fuel cooler line (2).
36. Connect the outlet fuel cooler line (3).
RAPH11TLB0037BA 25
37. Install the horn with horn bracket (1).
RAPH11TLB0035BA 26
38. Connect the air intake tube support bracket (2) and
bolts (1).
RAPH11TLB0030BA 27
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Index
Engine - 10

Engine - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Engine - Prepare for stall tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine - Service instruction - Engine repair service manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine - Speeds stall test check sheet (580N only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
580N NA T4
Engine - Speeds stall test check sheet (580SN WT only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
580SN WT NA T4
Engine - Speeds stall test check sheet (580SN only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
580SN NA T4
Engine - Speeds stall test check sheet (590SN only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
590SN NA T4
Engine - Speeds stall test normal (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Fuel tanks - 216
580N
580SN WT
580SN
590SN
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Contents
Engine - 10
Fuel tanks - 216
SERVICE
Fuel tank
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Engine - Fuel tanks
Fuel tank - Remove

WARNING
Fuel vapors are explosive and flammable.
Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove
key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.
W0904A
1. Support the fuel tank.
RCPH11TLB148AAM 1
2. Remove hardware.
3. Lower tank slightly.
RCPH11TLB148AAM 2
4. Disconnect fuel lines. Cap all open connections.
RCPH11TLB149AAM 3
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Engine - Fuel tanks
5. Disconnect fuel sending wire.
RCPH11TLB149AAM 4
6. Carefully remove the fuel tank.
RCPH11TLB150AAM 5
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Engine - Fuel tanks
Fuel tank - Install

WARNING
Fuel vapors are explosive and flammable.
Do not smoke while handling fuel. Keep fuel away from flames or sparks. Shut off engine and remove
key before servicing. Always work in a well-ventilated area. Clean up spilled fuel immediately.
W0904A
1. Carefully move the fuel tank into position.
RCPH11TLB150AAM 1
2. Remove caps and reconnect fuel lines.

3. Reconnect the fuel sending wire connection.
RCPH11TLB149AAM 2
4. Raise the tank slightly. Reinstall the mounting hard-

ware.
RCPH11TLB148AAM 3
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Index
Engine - 10
Fuel tanks - 216

Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Engine - 10
Engine cooling system - 400
580N
580SN WT
580SN
590SN
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Contents
Engine - 10
FUNCTIONAL DATA
Radiator
Exploded view - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
580N NA
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
580SN NA, 580SN WT NA, 590SN NA
SERVICE
Radiator
Remove - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
580N NA
Disassemble 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

580N NA
Assemble 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

580N NA
Install - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

580N NA
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
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Engine - Engine cooling system
Radiator - Exploded view - 580N only

580N NA
1. Deaeration tank 4. Mounting bolts

2. Radiator hose 5. Oil cooler connectors
3. Clamp 6. Condenser Pivot Bolt
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RCPH10TLB031GAL 1
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10.400 / 5
Radiator - Exploded view

1. Radiator 8. Transmission cooler tubes

2. Hydraulic oil cooler 9. Condenser and fuel cooler pivot bolts
3. Change air cooler 10. Oil cooler tubes
4. Air conditioning condenser 11. Fan shroud mounting bolts
5. Fuel cooler 12. Clamp
6. Transmission oil cooler 13. Deaeration tank
7. Charge air support bracket 14. Radiator hoses and clamps
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RCPH10TLB030GAL 1
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Radiator - Remove - 580N only

580N NA
NOTE: The photos in this procedure may be different from your machine and are for reference only.
1. Put identification tags on all disconnected hoses and
wires. Close disconnected hoses and fittings with
caps and plugs.
2. Park the machine on a level surface. Raise the
loader and lock the support strut (1) to hold the
loader. Stop the engine and apply the parking brake.
RCPH10TLB227AAF 1
3. Remove the cap screws, bumpers and the grill from

the front of the machine.
RCPH10TLB051AAL 2
4. Open the hood. Connect acceptable lifting equip-

ment to the hood.
RCPH10TLB356AAF 3
5. Do the following procedure to remove the hood:

A. Remove the retainers from the hood struts and
disconnect the hood struts from the stud.
B. Disconnect the hood cable from the radiator
shroud.
C. Carefully lower the hood back to the closed
position.
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6. Remove the bolts, washers, and nuts from the pivot

point on the hood.
RCPH10TLB046AAL 4
7. Drive the pivot tubes out of the hood pivot point. Re-
move the hood from the machine.
RCPH10TLB044AAL 5
8. Slowly remove the radiator cap. Install a hose on

the drain valve and drain the radiator into a clean
container that holds approximately 18 l (5 US gal).
RCPH10TLB050AAL 6
9. Loosen the clamp and disconnect the upper radiator

hose.
RCPH10TLB046AAL 7
10. Loosen the clamp and disconnect the lower radiator

hose.
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11. If equipped with air conditioning, discharge air con-

ditioning system. Disconnect high pressure switch,
disconnect hoses from condenser and receiver drier.
Remove the receiver drier and horn from the ma-
chine.
RCPH10TLB408ACL 8
12. Disconnect all four oil cooler hoses, two on each side
of the machine, from the oil cooler.
RCPH10TLB047AAL 9
13. Remove the radiator wrapper mounting bolts, re-

move the radiator wrapper from the machine.
RCPH10TLB053AAL 10
14. Attach suitable lifting equipment to the radiator.

Raise the cooling pack just enough to move it for-
ward and clear the fan.
RCPH10TLB053AAL 11
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15. Make sure that you have cleared the fan from the
shroud, raise the cooling pack from the machine.
RCPH10TLB048AAL 12
16. If applicable, see Radiator - Disassemble 580N

only (10.400) for procedures to replace worn or
damaged components.
Next operation:
Radiator - Install - 580N only (10.400).
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Radiator - Disassemble 580N only

580N NA
Prior operation:
Radiator - Remove (10.400)
1. Place cooling pack on a bench, if equipped remove

the condenser bracket mounting bolts, three per
side.
2. Remove the cooler line mounting clamps, remove
the oil cooler mounting bolts.
3. Remove the fan shroud mounting bolts, deaeration
tank , and radiator hoses from the radiator.
4. Replace worn or damaged components.
Next operation:
Radiator - Assemble (10.400)
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Radiator - Assemble 580N only

580N NA
Prior operation:
Radiator - Disassemble (10.400)
NOTE: Refer to the Radiator - Exploded view (10.400) for more details.
1. Install fan shroud and torque bolts to 13 - 25 N·m (10
- 18 lb ft).
2. Install deaeration tank.
3. Install radiator hoses and clamps, torque clamps to
4.5 - 5.5 N·m (40 - 49 lb in).
4. If fittings were removed from the oil cooler, install
fittings and torque to 77 - 85 N·m (57 - 63 lb ft).
NOTICE: Use two wrenches to minimize the torque trans-
mitted onto the elbow brazed to the oil cooler.
5. Install the oil coolers and tighten the mounting bolts.
6. Install the clamps and torque to 3.1 - 3.4 N·m (27 -
30 lb in).
7. Install the mounting brackets and tighten the mount-
ing bolts.
8. If equipped, mount the condenser into the bracket
using the pivot bolt.
9. Tighten the condenser pivot bolt tight enough to
remove the gaps between the mounting brackets
but not tight enough to prevent the condenser from
swinging out for cleaning.
10. Swing the condenser into position, install and tighten
retaining bolts.
Next operation:
Radiator - Install (10.400)
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Radiator - Install - 580N only

580N NA
NOTE: The photos in this procedure may be different from your machine and are for reference only.
1. Attach suitable lifting equipment to the radiator.
2. Lower the assembly just in front of the fan and slowly
guide the cooling pack backward clearing the fan.
NOTE: Adjust fan shroud to obtain 20 mm (0.8 in) around
the fan.
RCPH10TLB048AAL 1
3. Install the radiator wrapper and secure with mounting

bolts on both sides of the machine.
RCPH10TLB053AAL 2
4. Connect all four oil cooler hoses, two on each side of

the machine.
RCPH10TLB047AAL 3
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5. Install the receiver drier and horn on the machine.

Connect high pressure switch, connect the hoses
from condenser and receiver drier. If equipped with
air conditioning, see Air conditioning - Charging -
Air conditioner system evacuation and recharg-
ing (50.200) to charge the system.
RCPH10TLB408ACL 4
6. Connect the lower radiator hose and tighten the

clamp.
7. Connect the upper radiator hose and tighten the
clamp.
RCPH10TLB054AAL 5
8. Position the hood on the machine and drive the pivot

tubes into the hood pivot point.
RCPH10TLB044AAL 6
9. Secure the hood to the pivot point with the bolts,

washers, and nuts.
RCPH10TLB046AAL 7
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10. Do the following procedure to secure the hood:

A. Carefully place the hood in a raised position.
B. Attach the hood cable to the radiator shroud.
C. Attach the hood struts to the stud and secure
with the retainers .
11. Disconnect the lifting equipment from the hood .
RCPH10TLB356AAF 8
12. Install the front grill, bumpers, and secure in place

with the cap screws (1).
RCPH10TLB051AAL 9
13. Fill the radiator and deaeration reservoir to the full

line. See Capacities () for specifications.
14. Connect the battery.
15. Start the engine and allow the coolant to reach op-
erating temperature. Stop the engine and check for
leaks. After the coolant cools check the level and fill
as needed.
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Radiator - Remove
Prior operation:
Battery - Basic instructions (55.302)
Prior operation:
Engine hood - Remove (90.105)
1. Remove grill hardware.
RCPH11TLB009AAM 1
2. Remove grill bumpers.
RCPH11TLB010AAM 2
3. Remove the grill.
RCPH11TLB032AAM 3
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4. Drain the coolant.
RCPH11TLB011AAM 4
RCPH11TLB012AAM 5
5. Remove the radiator purge hose.
RCPH11TLB013AAM 6
6. Remove the upper radiator hose.
RCPH11TLB014AAM 7
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7. Remove the charge air cooler hoses and pipes.
RCPH11TLB015AAM 8
8. Cap (seal) all open ports to keep contaminates from

entering the system.
RCPH11TLB016AAM 9
9. Remove the lower radiator hose.
RCPH11TLB017AAM 10
10. Discharge the A/C system.

NOTICE: Use appropriate reclaiming devices when recov-
ering A/C refrigerant.
RCPH11TLB018AAM 11
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11. Disconnect the high pressure switch.
RCPH11TLB019AAM 12
12. Remove the horn.
RCPH11TLB020AAM 13
13. Disconnect A/C receiver dryer lines and cap all open
ports.
RCPH11TLB021AAM 14
14. Remove the dryer.
RCPH11TLB022AAM 15
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15. Disconnect the upper condenser line and cap all

open ports.
RCPH11TLB023AAM 16
16. Disconnect fuel cooler lines and cap open ports.
RCPH11TLB024AAM 17
17. Tag and disconnect the four oil cooler lines and cap
all open ports.
Left hand oil cooler lines Right hand oil cooler lines
RCPH11TLB026AAM 18 RCPH11TLB025AAM 19
18. Remove the radiator wrapper mounting bolts.
RCPH11TLB027AAM 20
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19. Remove the radiator wrapper.
RCPH11TLB028AAM 21
20. Remove hood strut mounts.
RCPH11TLB029AAM 22
21. Remove hood hinge plates.
RCPH11TLB029AAM 23
22. Attach a suitable lifting device.
RCPH11TLB030AAM 24
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23. Remove cooling package mounting hardware.
RCPH11TLB029AAM 25
24. Remove cooling package.
RCPH11TLB031AAM 26
Next operation:
Radiator - Install (10.400).
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Radiator - Disassemble
Prior operation:
Radiator - Remove (10.400)
1. Place cooling pack on a bench, remove the charge

air support bracket mounting bolts, three per side.
2. Remove the cooler line mounting clamps, remove
the oil cooler mounting bolts.
3. Remove the fan shroud mounting bolts, deaeration
tank, and radiator hoses from the radiator.
4. Replace worn or damaged components.
Next operation:
Radiator - Assemble (10.400)
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Radiator - Assemble
Prior operation:
Radiator - Disassemble (10.400)
NOTE: Refer to the Radiator - Exploded view (10.400) for more details.
1. Install fan shroud and torque bolts to 13 - 25 N·m (10
- 18 lb ft).
2. Install deaeration tank.
3. Install radiator hoses and clamps, torque clamps to
4.5 - 5.5 N·m (40 - 49 lb in).
4. If fittings were removed from the oil cooler, install
fittings and torque to 77 - 85 N·m (57 - 63 lb ft).
NOTICE: Use two wrenches to minimize the torque trans-
mitted onto the elbow brazed to the oil cooler.
5. Install the oil coolers and tighten the mounting bolts.
6. Install the clamps and torque to 3.1 - 3.4 N·m (27 -
30 lb in).
7. Install the charge air cooler mounting brackets and
tighten the mounting bolts.
8. If equipped with fuel cooler and condenser, mount
the charge air cooler and the mounting brackets for
the condenser and fuel cooler, tighten the mounting
bolts.
9. Mount the condenser and fuel cooler onto the bracket
using the pivot bolt.
10. Tighten the condenser and fuel cooler pivot bolt tight
enough to remove the gaps between the mounting
brackets but not tight enough to prevent the compo-
nents from swinging out for cleaning.
11. Swing the condenser and fuel cooler into position,
install and tighten retaining bolts.
Next operation:
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Radiator - Install
1. Carefully lower the cooling package into place.
RCPH11TLB031AAM 1
2. Install the cooling package with the existing mounting

hardware.
RCPH11TLB029AAM 2
3. Remove the lifting device.
RCPH11TLB030AAM 3
4. Install hood hinge plates.
RCPH11TLB029AAM 4
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5. Install hood strut mounts.
RCPH11TLB029AAM 5
6. Install the radiator wrapper.
RCPH11TLB028AAM 6
7. Install the radiator wrapper mounting bolts.
RCPH11TLB027AAM 7
8. Remove the caps and install the four oil cooler lines.
Left hand oil cooler lines Right hand oil cooler lines
47365539 08/07/2012
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9. Connect fuel cooler lines and remove the caps from

the open ports.
RCPH11TLB024AAM 10
10. Remove the cap and install the upper condenser line.
RCPH11TLB023AAM 11
11. Move the dryer into place and secure to the frame.
RCPH11TLB022AAM 12
12. Remove all caps and reconnect A/C receiver dryer

lines.
RCPH11TLB021AAM 13
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13. Install the horn.
RCPH11TLB020AAM 14
14. Connect the high pressure switch.
RCPH11TLB019AAM 15
15. Install the lower radiator hose.
RCPH11TLB017AAM 16
16. Remove the caps from the open ports.
RCPH11TLB016AAM 17
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17. Install the charge air cooler hoses and pipes.
RCPH11TLB015AAM 18
18. Install the upper radiator hose.
RCPH11TLB014AAM 19
19. Install the radiator purge hose.
RCPH11TLB013AAM 20
20. Install the grill.
RCPH11TLB032AAM 21
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21. Install the grill bumpers.
RCPH11TLB010AAM 22
22. Install all grill hardware.
RCPH11TLB009AAM 23
23. Refill the system with coolant.
RCPH10TLB032AAF 24
24. Recharge the A/C system.
RCPH11TLB018AAM 25
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Index
Engine - 10

Radiator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Radiator - Assemble 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
580N NA
Radiator - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Radiator - Disassemble 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
580N NA
Radiator - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Radiator - Exploded view - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
580N NA
Radiator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Radiator - Install - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
580N NA
Radiator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Radiator - Remove - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
580N NA
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Engine - 10
Exhaust Gas Recirculation (EGR) exhaust treatment - 501
580N
580SN WT
580SN
590SN
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Contents
Engine - 10
FUNCTIONAL DATA
Particulate filters
Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N T4, 580SN T4, 580SN WT T4, 590SN T4
SERVICE
Particulate filters
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
580N T4, 580SN T4, 580SN WT T4, 590SN T4
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Engine - Exhaust Gas Recirculation (EGR) exhaust treatment
Particulate filters - Dynamic description

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Overview
Loader backhoes built beginning of 2012 and later are equipped with the Diesel Particulate Filter (DPF) engine ex-
haust emission control system. These engines also have a common rail electronic fuel injection system. During
normal operation the diesel engine generates certain pollutants. Federal law has regulated the levels of these ex-
haust components that a vehicle is allowed to emit. Pollutants generated in the normal operation of these engines
require after treatment. The Diesel Particulate Filter (DPF) emissions control system controls these pollutants.
The DPF system typically uses a cooled Exhaust Gas Recirculation System to minimize the generation of NOx polu-
tants. The system then uses a Diesel Oxidation Catalyst (DOC) (1) to treat and convert the NOx to harmless gases.
The Diesel Particulate Filter (DPF) (2) traps the particulate matter (PM) or soot, generated during the combustion cy-
cle. The DPF can be cleaned by elevating the exhaust system temperature and burning the PM. The Engine Control
Unit (EDC17C49) (3) controls the engine fuel injection and the exhaust gas recirculation. The EDC17C49 controls the
speed and power output of the engine as well as minimizes the generation of NOx pollutants. The EDC also receives
sensor inputs from the DPF system sensors.
The heated exhaust gas oxygen sensor (HEGO) (4) provides combustion system efficiency information to the EDC.
The EDC can use that information to determine the fuel injection requirements. The exhaust temperature must reach
a minimum temperature for the DOC and DPF to function effectively. The DOC inlet temperature sensor (5) monitors
the exhaust stream temperature at the inlet to the DOC. The DPF inlet temperature sensor (6) monitors the actual
temperature at the inlet of the DPF system. Restricting the generation of NOx requires that the combustion temper-
ature be reduced. This lower combustion temperature causes the generation of additional particulate matter (PM) or
soot. The DPF traps this PM as the exhaust passes through. This trapped PM continuously builds up in the DPF. The
DPF can be cleaned by elevating the exhaust temperature and burning the PM. This cleaning process is referred to
as regeneration. The restriction of the DPF caused by particulate matter is monitored by the DPF differential pressure
sensor (7) which measures the inlet and outlet pressure of the DPF. The EDC (3) automatically triggers the regener-
ation process as required.
RAIL12TLB0079EA 1
1. Diesel Oxidation Catalyst (DOC) 5. DOC Inlet Temperature Sensor

2. Diesel Particulate Filter (DPF) 6. DPF Inlet Temperature Sensor
3. Engine Control Unit (EDC17C49) 7. DPF Differential Pressure Sensor
4. Heated Exhaust Gas Oxygen Sensor (HEGO)
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Diesel Particulate Filter (DPF) System Components Involved:

The main components of DPF system are:
• 3.4 liter F5C Fiat Power Train engine with common rail fuel injection system
• DPF System Sensors
1. Exhaust manifold temperature sensor (17) A temperature sensor mounted within the exhaust manifold
to monitor the combustion temperature of the engine.
2. Exhaust manifold pressure sensor (18) A pressure sensor mounted in the exhaust manifold to monitor
the back pressure of the exhaust system.
3. Waste gate Turbo pressure modulator (28). Mounted on the engine to compare the turbo boost pressure
and the turbo inlet pressure. Controls the pressure to the turbo waste gate diaphragm controlling the
turbo boost pressure.
4. Heated Exhaust Gas Oxygen Sensor (HEGO), (30). Mounted to the exhaust pipe near the inlet of the
Oxidation Catalyst. Monitors the oxygen content of the exhaust stream.
5. Diesel Oxidation Catalyst inlet temperature sensor, (31). Mounted in the inlet of the DPF assembly.
Monitors the actual exhaust temperature at the inlet to the catalyst. The catalyst must be at least 200
°C (392 °F) to function.
6. Diesel Particulate Filter (DPF) inlet temperature sensor, (33). The DPF inlet temperature sensor is
mounted to the side of the DPF assembly and monitors the temperature of the exhaust gases flowing
through the DPF.
7. DPF Differential pressure sensor, (35). The differential pressure sensor is mounted to a bracket on the
DPF assembly. The amount of particulate matter (PM) or soot generated varies during engine operation.
The differential pressure sensor monitors the restriction of the DPF caused by the PM buildup. The
regeneration cycle is triggered at preselected restriction levels.
• EGR Valve with Position Feedback (19). The EGR valve is mounted at the rear of the engine, connected to
the exhaust manifold. The EGR valve controls the recirculation of exhaust gas into the intake manifold. This
recirculation limits the generation of NOx during the combustion cycle. The position feedback feature reports
the actual position of the valve to the engine controller. This allows for much more precise control.
• Exhaust Gas Recirculation (EGR) Cooler (20). The EGR cooler is mounted at the top of the engine between
the EGR valve and the intake manifold. The cooler uses engine coolant to remove exhaust heat from the EGR
gases prior to recirculating back to the intake manifold.
• Diesel Oxidation Catalyst (32). The oxidation catalyst is the first section of the DPF assembly. The catalyst
converts the NOx in the exhaust stream to harmless gases and water.
• Diesel Particulate Filter (DPF) (34). The DPF captures particulate matter (PM) or soot in the exhaust stream.
Once the filter begins to plug, the engine controller introduces extra fuel into the combustion process. This
excess fuel causes the exhaust temperature to elevate which burns off the PM or soot to an ash. This process
is called regeneration. After approximately 3000 hours the DPF must be remanufactured to remove built up
particles.
• Throttle Valve (TVA) with Position Feedback (16). The intake throttle valve is mounted at the inlet of the intake
manifold. This throttle valve restricts the air flow through the engine during forced or manual regeneration of the
DPF. Limiting the air flow causes the engine exhaust temperature to elevate to burn the particulate matter (PM)
in the DPF. The position feedback feature reports the actual position of the valve to the engine controller. This
allows for much more precise control.
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RAIL12TLB0077FA 2
F5C Tier 4a N Series Loader Backhoe Fuel and Emission System – above 56kW
Component Locations:
• Black = Engine mounted
• Red = Vehicle mounted
• Blue = Exhaust pipe mounted
F5C Tier 4a Diesel Particulate Filter (DPF) System Components

14. Turbocharger Compressor 30. Heated Exhaust Gas Oxygen Sensor (HEGO)
16. Intake Throttle Valve (TVA) 31. DOC Inlet Temperature Sensor
17. Exhaust Manifold Temperature Sensor (T3) 32. Diesel Oxidation Catalyst (DOC)
18. Exhaust Manifold Pressure Sensor (P3) 33. DPF Inlet Temperature Sensor
19. EGR Valve with Position Feedback 34. Diesel Particulate Filter (DPF)
20. Exhaust Gas Recirculation (EGR) Cooler 35. DPF Differential Pressure Sensor
23. Engine 44. Turbocharger Waste Gate Diaphragm
28. Waste Gate Turbo Pressure Modulator 45. Turbocharger Waste Gate Valve
29. Fixed Geometry Turbocharger Turbine
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• Fixed Geometry Turbocharger Turbine (29) with Waste Gate Valve (45). The waste gate turbo uses energy in
the heated exhaust gas to power the turbine (29) which drives the turbocharger compressor (14) to force air
into the intake. The fixed geometry turbocharger (29) is equipped with a waste gate valve (45). Turbochargers
equipped with a waste gate are sized larger than the engine can use at full power. This larger size allows the
turbo to be able to provide boost pressure and improved engine performance at lower speeds and lighter engine
loads. To prevent the turbo from over pressurizing the system at full power, the waste gate diaphragm (44) opens
the waste gate valve (45) bypassing exhaust across the turbine to limit the boost pressure.
• Waste Gate Turbo Pressure Modulator (28). The waste gate diaphragm (44) is controlled by the waste gate
turbo pressure modulator (28). The pressure modulator monitors both the turbo boost pressure at the intake
manifold and the intake air pressure at the inlet of the turbo compressor (14). Based on this comparison, the
modulator sends boost pressure to the diaphragm (44) which limits the maximum boost pressure.
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RAIL12TLB0077FA 3
F5C Tier 4a N Series Loader Backhoe Fuel and Emission System – above 56kW
Component Locations:
• Black = Engine mounted
• Red = Vehicle mounted
• Blue = Exhaust pipe mounted
F5C Tier 4a Diesel Particulate Filter (DPF) System Components

14. Turbocharger Compressor 30. Heated Exhaust Gas Oxygen Sensor (HEGO)
16. Intake Throttle Valve (TVA) 31. DOC Inlet Temperature Sensor
17. Exhaust Manifold Temperature Sensor (T3) 32. Diesel Oxidation Catalyst (DOC)
18. Exhaust Manifold Pressure Sensor (P3) 33. DPF Inlet Temperature Sensor
19. EGR Valve with Position Feedback 34. Diesel Particulate Filter (DPF)
20. Exhaust Gas Recirculation (EGR) Cooler 35. DPF Differential Pressure Sensor
23. Engine 44. Turbocharger Waste Gate Diaphragm
28. Waste Gate Turbo Pressure Modulator 45. Turbocharger Waste Gate Valve
29. Fixed Geometry Turbocharger Turbine
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Regeneration function
The DPF system uses a combination Diesel Oxidation Catalyst (DOC) and a Diesel Particulate Filter (DPF). The
oxidation catalyst converts the NOx in the exhaust stream to harmless gases and water. The diesel particulate filter
(DPF) traps the particulate matter (PM) or soot in the exhaust stream that is generated during combustion. The
filter can be “cleaned” by elevating the exhaust temperature and burning the PM. This “cleaning” process is called
regeneration. The exhaust temperature must reach approximately 600 °C (1112 °F). The elevated temperature in the
exhaust stream is caused by introducing fuel into the cylinder late in the combustion cycle or post injection. The fuel
injectors in the common rail system have the capability of injecting fuel more than one time during each combustion
cycle. The early pilot and pre-injections are typically for noise control. During regeneration, late and post injections
cause the exhaust stream temperature to elevate and burn off the PM. Regeneration cycles can either be triggered
automatically by the engine controller or manually/forced by the operator.
Automatic regeneration
The engine control module that activates the automatic regeneration cycle as the DPF begins to plug. During both
“Auto” and “Forced” regeneration, fuel is injected after the main injection when the temperature is below approximately
250 °C (482 °F) at the DOC and DPF. This increases exhaust gas temperature to assist in “burning off” particulate
matter (PM). The machine can continue to work during automatic regeneration. The Advanced Instrument Cluster
(AIC) will indicate that automatic regeneration is active. When the exhaust temperature is above 250 °C (482 °F) at
the DOC and DPF, there is an additional injection to help create hotter exhaust gas temperatures. The intent is to
gradually build-up heat to burn off PM; as opposed to an initial burst of extreme heat which could damage the DPF.
Automatic regeneration can be interrupted by activating the forced regeneration switch during automatic regeneration
or shutting the keyswitch off.
During the auto regeneration process an increase in engine noise level may be observed.
During the auto regeneration process a burning or “hot” odor may be present. The operator may continue to operate
the machine normally during the auto regeneration process. When engine load is high enough regeneration may
happen. If the load drops, regeneration may stop early. The auto regeneration process will last approximately 5 – 20
minutes depending on the ash level in the DPF and current machine operations. The advanced instrument cluster
(AIC) communicates auto regeneration information to the operator.
Loader backhoe DPF auto regeneration

1. Operator is notified of the beginning of Auto Regen-
eration by a single audible beep and the DPF re-
generation ON symbol appears on the AIC display
screen. The DPF regeneration process begins and
the display will alternate between the DPF ON sym-
bol and the hour meter, approximately 10 times.
RCPH11TLB006AAD 4
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2. After the regeneration process is complete a single

audible beep and the DPF regeneration OFF symbol
will appear on the AIC display screen. The display
will alternate between the DPF OFF symbol and the
hour meter, approximately 10 times
RCPH11TLB005AAD 5
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Regeneration inhibit
The instrument cluster displays information about the function of the DPF system. The cluster can inhibit the auto
regeneration process or force the regeneration process to begin based on input commands from the operator. The
default setting of the instrument cluster is to allow the DPF system to auto regenerate any time that it is triggered by
the engine controller. Under certain conditions the operator may want to delay the regeneration process at that time.
However, continuing to delay the auto regeneration process will eventually result in a forced regeneration because of
a buildup of exhaust soot in the DPF
The AIC regeneration inhibit Selection screen allows the operator to delay the DPF auto regeneration process during
the current key cycle.
NOTE: The regeneration inhibit feature returns to the enable setting by default at the next key cycle.
NOTE: The operator may choose to delay the auto regeneration process. However, continuing to delay the auto
regeneration process will eventually require a forced regeneration.
Loader backhoe DPF regeneration inhibit:

Disable the regeneration inhibit feature:
1. Press Enter (1) to access the menu screens.
2. Press the up arrow (2) or the down arrow (3) to nav-
igate through the menu screens.
RCPH10TLB140AAF 6
3. When the regeneration inhibit Selection screen dis-

plays, press Enter. The menu screen flashes.
RCPH11TLB008AAD 7
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4. Press Enter to disable the regeneration inhibit

process. The display screen changes to indicate
the feature is disabled.
NOTE: The regeneration inhibit disabled image will
reappear on a consistent basis with an audible alert
until the operator enables the feature or turns the
machine off.
RCPH11TLB007AAD 8
5. Use the arrows to navigate to a different menu

screen or press Escape (4) until you return the main
screen (engine hour meter).
RCPH10TLB140AAF 9
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Forced regeneration
Forced regeneration requires an operator command. A differential pressure sensor monitors the particulate matter
(PM) buildup in the DPF. If the automatic regeneration process is interrupted or does not adequately remove the
PM, the DPF will begin to become obstructed. When the differential pressure sensor senses this obstruction, the
instrument cluster will display a warning and activate an audible alarm to instruct the operator to command a forced
regeneration. If the operator does not force the regeneration as indicated, the engine controller limits the engine
torque. At the first level of restriction, the engine torque will reduce to approximately 50%. If the restriction continues
to build, the engine torque will reduce to approximately 33%.
The operator must then activate the forced regeneration process. If forced regeneration is commanded while auto-
matic regeneration is active, the automatic cycle turns off and the forced cycle becomes active. To activate forced
regeneration, specific conditions must be met. These are, throttle at minimum position, vehicle speed at zero if speed
is monitored, otherwise park brake engaged, PTO not engaged, and hydraulics not active.(********If one of the condi-
tions have not been met, the instrument cluster will display the problem. (This needs to be validated)) During forced
regeneration, the machine must remain at idle and cannot be used. Cyclical loads can cause the forced regeneration
to stop so features such as Air Conditioning must be turned off prior to forcing regeneration. Manual or forced regen-
eration can be suspended by operating the accelerator or pressing the activation switch again. Care should be taken
to normally allow the forced regeneration process to complete once it has been initiated.
The operator may NOT continue to operate the machine normally during the forced regeneration process.
During the forced regeneration process an increase in engine noise level may be observed.
During the forced regeneration process a burning or “hot” odor may be present.
The forced regeneration process will last approximately 20 minutes depending on the ash level in the DPF.
If the forced generation process is not allowed the machine will begin to de-rate. Damage or shortened DPF life may
occur if the forced regeneration is ignored for an extended period of time.
WARNING CAUTION
Fire hazard! Burn hazard!
During the Diesel Particular Filter (DPF) forced During the Diesel Particular Filter (DPF) regen-
regeneration process the exhaust stack and eration process the exhaust stack and fixed
fixed hood area becomes extremely hot. Park hood area becomes extremely hot. Allow area
the machine outside and away from com- to cool before servicing or working near the
bustible or highly flammable material. exhaust system components.
Failure to comply could result in death or se- Failure to comply could result in minor or
rious injury. moderate injury.
W1165A
C0102A
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Loader backhoe forced regeneration

1. Operator will be notified with one of the following:
Extended audible alert, amber LED and

the DPF regeneration PARK symbol will ap-
pear on the display screen. Indicating a high
level of ash is present in the DPF system.
Constant audible alert, red LED and the

DPF regeneration PARK symbol will appear
on the display screen. Indicating an extremely
high level of ash is present in the DPF system.
RCPH11TLB004AAD 10
2. Calmly find a location out of the way on the job site

and clear away from any combustible material. Per-
form the following:
A. Put the machine in Neutral.
B. Engage parking brake.
C. Put both the hand and foot throttles in their idle
position.
D. Wait for the DPF regeneration START symbol
to appear on the display.
NOTE: Changing any of the above conditions
during the forced regeneration process will
11
cause the process to FAIL. RCPH11TLB003AAD
3. Press enter.
RCPH10TLB140AAF 12
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4. DPF regeneration WAIT symbol appears. The sys-

tem is validating machine readiness and all actions
in step 2 have been completed
RCPH11TLB002AAD 13
5. One of the following will occur:
• DPF regeneration ON symbol appears indicating

the regeneration process has started, allow approx-
imately 20 minutes to complete.
RCPH11TLB006AAD 14
• DPF regeneration FAIL symbol appears indicating

the machine is not ready. Repeat step 2.
NOTE: If the DPF regeneration continues to FAIL
contact your authorized dealer for service.
RCPH11TLB010AAD 15
6. DPF regeneration OFF symbol appears indicating

the regeneration process is complete. Machine is
ready for operation
RCPH11TLB005AAD 16
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Particulate filters - Remove

580N T4, 580SN T4, 580SN WT T4, 590SN T4
CAUTION
Burn hazard!
During the Diesel Particular Filter (DPF) regeneration process the exhaust stack and fixed hood area
becomes extremely hot. Allow area to cool before servicing or working near the exhaust system com-
ponents.
Failure to comply could result in minor or moderate injury.
C0102A
1. Disconnect the aspirator tube (1).
RAPH11TLB0052BA 1
2. Remove the air cleaner assembly (1).
RAPH11TLB0050BA 2
3. Remove the fixed engine hood (1).
RAPH11TLB0051BA 3
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4. Label and disconnect the Lambda sensor electrical

connector (3).
5. Label and disconnect the exhaust gas temperature
sensors (4).
6. Remove the DPF pipe hold-down bolt and clamp (2).
7. Disconnect the differential pressure sensor tubes
from the DPF pipes (1).
8. Disconnect the exhaust pipe (5).
9. Remove the DPF hold-down bolts and clamps (6).
RAPH11TLB0053BA 4
10. Remove the DPF.
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Particulate filters - Install

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1. Place the DPF on the DPF tray.

2. Connect the Lambda sensor electrical connector (3).
3. Connect the exhaust gas temperature sensors (4).
4. Connect the differential pressure sensor tubes to the
DPF pipes (1).
5. Install the DPF pipe hold-down clamp and bolt (2).
6. Connect the exhaust pipe (5).
7. Install the DPF hold-down clamps and bolts (6).
RAPH11TLB0053BA 1
8. Install the fixed engine hood (1).

9. Remove the exhaust stack (2) from the fixed hood
and confirm the DPF exhaust tube is centered in the
opening. Make adjustments to the positioning of the
DPF and its components as necessary.
NOTICE: Alignment of the exhaust stack and DPF tube
provides a clear path for the high temperature DPF exhaust
to properly exit the machine area. If not aligned properly
damage to the painted finish on the fixed hood may occur
as well as increased temperatures on the fixed hood during
the regeneration procedure.
RAPH11TLB0051BA 2
10. Install the air cleaner assembly (1).
RAPH11TLB0050BA 3
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11. Connect the aspirator tube (1).
RAPH11TLB0052BA 4
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Index
Engine - 10

Particulate filters - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Particulate filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Particulate filters - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
580N T4, 580SN T4, 580SN WT T4, 590SN T4
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CNH - Main 700 State Street Racine, Wisconsin United States 53404
SERVICE - Technical Publications & Tools
PRINTED IN U.S.A.
© 2012 CNH America LLC.
All rights reserved. No part of the text or illustrations of this publication may be reproduced.
CASE CONSTRUCTION policy is one of continuous improvement and the right to change prices, specification
or equipment at any time without notices is reserved.
All data given in this publication is subject to production variations. Dimensions and weight are approximate only
and the illustrations do not necessarily show products in standard condition. For exact information about any
particular product, please consult your CASE CONSTRUCTION Dealer.
47365539 08/07/2012
EN
SERVICE MANUAL
Transmission
580N
580SN WT
580SN
590SN
47365539 08/07/2012
21
Contents
Transmission - 21
Power Shuttle transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.112

580N , 580SN WT , 580SN , 590SN
Powershift transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.113

580N , 580SN WT , 580SN , 590SN
Power Shuttle transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.134

580N , 580SN WT , 580SN , 590SN
Powershift transmission external controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.135

580N , 580SN WT , 580SN , 590SN
Power Shuttle transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.154

580N , 580SN WT , 580SN , 590SN
Powershift transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.155

580N , 580SN WT , 580SN , 590SN
47365539 08/07/2012
21
Transmission - 21
Power Shuttle transmission - 112
580N
580SN WT
580SN
590SN
47365539 08/07/2012
21.112 / 1
Contents
Transmission - 21
TECHNICAL DATA
Power Shuttle transmission

Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exploded view - Four wheel drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exploded view - Two wheel drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydraulic schema - Two Wheel Drive Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydraulic schema - Four Wheel Drive Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Check Checking Supply Pump Pressure (4WD Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Test - Checking Converter In Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Test - Checking Regulated Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Test Checking Supply Pump Flow and Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Test - Checking Converter Out Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Test Checking Lubrication Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Test - Checking Differential Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Pressure test – 2 Wheel Drive, Test One - Engine at Idle 900 to 1100 rpm . . . . . . . . . . . . . . . . . . . . . . . . 42
Pressure test - 2 Wheel Drive, Test Two - Engine at 2200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Tool connection Two Wheel Drive Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Tool connection - Pressure Test Ports, Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Tool connection Pressure Test Ports 4 Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Tool connection Four Wheel Drive Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Pressure test – 4 Wheel Drive, Test One - Engine at Idle 900 to 1100 rpm . . . . . . . . . . . . . . . . . . . . . . . . 48
Pressure test - 4 Wheel Drive, Test Two - Engine at 2200 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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Transmission housing
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disassemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Disassemble - Shift rods and shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Assemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Assemble - Transmission housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
DIAGNOSTIC

Testing - Machine Will Not Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Testing - Will Not Go Into 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Testing - Machine Hesitates When Shifting Between Forward and Reverse . . . . . . . . . . . . . . . . . . . . . . 100
Testing - Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Testing - Transmission Oil is Too Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Testing Problem in the Parking Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
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Transmission - Power Shuttle transmission
Power Shuttle transmission - General specification

Type of transmission oil MS-1209, Hy-Tran™ Ultra
Clutch disc clearance 2.3 - 4.3 mm (0.1 - 0.2 in)
Capacity - Two wheel drive

Refill capacity with or without filter change 16 l (16.9 US qt)
Capacity - Four wheel drive

Total system 21 l (22.2 US qt)
Refill capacity with or without filter change 18.5 l (19.5 US qt)
Specifications
NOTE: All specifications shown were taken from a sampling of new production machines with less than 20 hours.
Your figures may differ slightly depending upon the temperature, instrument variables, engine hours, etc.
Parameter Operating Pressure / Temperature

Output of pump supply 32 - 68 l/min (8.5 - 18.0 US gpm) at 900 - 2200 RPM
Pump supply pressure (4WD) 1248 - 1551 kPa (181 - 225 psi) at 900 - 2200 RPM
Regulated clutch pressure 1103 - 1303 kPa (160 - 189 psi) at 900 - 2200 RPM
Torque pressure IN pressure 48 - 903 kPa (7 - 131 psi) at 900 - 2200 RPM
Torque converter OUT pressure 0 - 427 kPa (0 - 62 psi) at 900 - 2200 RPM
Lubrication pressure 40 - 303 kPa (6 - 44 psi) at 900 - 2200 RPM
Transmission oil operating temperature (normal) 78 - 82 °C (172 - 180 °F)
Forward/Reverse clutch solenoids 4.7 ± 10% Ohm at 20 °C (68 °F)
Four wheel drive solenoid 6.8 ± 10% Ohm at 20 °C (68 °F)
Park brake solenoid 9.8 Ohm at 20 °C (68 °F)
Differential lock solenoid valve pressure
Without differential lock solenoid energized 0 bar (0 psi)
With differential lock solenoid energized (4WD) 12.5 - 15.5 bar (181.3 - 224.8 psi)
With differential lock solenoid energized (2WD) and 11 - 13 bar (159.5 - 188.5 psi)
direction control lever in Forward or Reverse position
Park brake check port 13.5 - 15.5 bar (195.8 - 224.8 psi)
NOTICE: Vehicle may move during park brake pressure check. Check park brake pressure from inside of the cab by
removing the floor plate.
Power Shuttle transmission - Torque

Pipe plug in end of four-wheel drive shaft 30 N·m (265.5 lb in)
Solenoid valve in four-wheel drive valve 22.0 N·m (194.7 lb in)
Nut for solenoid coils on transmission control valve 7 - 10 N·m (62.0 - 88.5 lb in)
Fittings for four-wheel drive clutch tube 30 N·m (265.5 lb in)
Allen head screws for valve plate on front housing 23 N·m (203.6 lb in)
Test port plugs 23 N·m (203.6 lb in)
Detent plugs 80 N·m (59.0 lb ft)
Bolts for rear cover 50 N·m (36.9 lb ft)
Bolt for output flange 139 N·m (102.5 lb ft)
Allen head screws for shifter assembly 23 N·m (203.6 lb in)
Hollow cap screws for tube on front housing 40 N·m (354.0 lb in)
Bolts to fasten front and rear housings 50 N·m (36.9 lb ft)
Bolts to fasten cover below four-wheel drive flange 23 N·m (203.6 lb in)
Bolt for four-wheel drive flange 139 N·m (102.5 lb ft)
Bolts for oil pump 23 N·m (203.6 lb in)
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Fitting for oil filter 50 N·m (36.9 lb ft)

Bolts to fasten four-wheel drive valve to front housing 23 N·m (203.6 lb in)
Bolts to fasten cover for oil screen 23 N·m (203.6 lb in)
Bolts for transmission control valve 23 N·m (203.6 lb in)
Drain plug 80 N·m (59.0 lb ft)
Allen head screws to fasten pump support to pump 10 N·m (88.5 lb in)
housing
Nut for four-wheel drive solenoid coil 8 N·m (70.8 lb in)
Allen head screws for modulation cover 11 N·m (97.4 lb in)
Solenoid plunger in transmission control valve 23 N·m (203.6 lb in)
Bolts to fasten pump mount to rear housing 50 N·m (36.9 lb ft)
Power Shuttle transmission - Special tools

CAS-1804 Pressure Fitting Kit
RCPH11TLB020BAL 1
CAS-40033 Transmission Tool Kit
RCPH11TLB021BAL 2
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CAS-1808 Flowmeter Fitting Kit
RCPH11TLB022BAL 3
CAS-2011 Filter base adapter used with CAS-2383 filter

adapter tube from CAS-40033, Transmission Tool Kit
RCPH11TLB023BAL 4
CAS-10280 Flowmeter
RCPH11TLB024BAL 5
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380040161 - Teflon seal installation
RCPH10TLB828AAL 6
CAS-2379 Input shaft holder and spring compressor
RCPH10TLB043ABL 7
CAS-2381 Seal driver
RCPH10TLB045BL 8
CAS-2378 transmission leg set
RCPH10TLB044ABL 9
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CAS2771A - Teflon seal installation tool kit - 4 wheel drive

shaft
RCPH10TLB688AAL 10
1. CAS2771-2 Seal Expander/Protector

2. CAS2771-1 Seal Compressor
3. CAS2771-3 Spacer
4. CAS2327 Pusher
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Power Shuttle transmission - Exploded view

1. Nut (2) 90-100 NM (67 - 73 lb-ft) 8. Backing plate
2. Transmission 9. Cap screw (4) 52-57 NM (38-42 lb-ft)
3. Bolt (12) 52-57 NM (67-73 lb-ft) 10. Bolt (4) 52-57 NM (38 - 42 lb-ft)
4. Dipstick tube 11. Nut 90-100 NM (67 - 73 lb-ft)
5. Converter 12. Rubber transmission mount (2)
6. Flex plate with caged nut 13. Constant torque clamp (4) 5.6 - 7.9 NM (50 - 50 in-lb)
7. Flex plate
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RCPH10TLB5GAL 1
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Power Shuttle transmission - Exploded view - Four wheel drive

transmission
Four-wheel drive transmission
1. Tube 13. Breather
2. Hollow bolt 14. Breather pipe
3. Copper washer 15. PTO flange
4. Copper washer 16. O-ring
5. Plug 17. Bolt
6. Plug 18. Rear cover
7. Plug 19. Bolt
8. O-ring 20. Dowel pin
9. Fitting 21. Drain plug
10. Copper washer 22. Rear housing
11. Test port plug 23. Four-wheel drive clutch tube
12. Park brake pressure tube 24. Front housing
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RCPH10TLB020GAL 1
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Power Shuttle transmission - Exploded view - Two wheel drive

transmission
Two-wheel drive transmission
1. Tube 11. Dowel pin
2. Hollow bolt 12. Park brake pressure tube
3. Copper washer 13. Rear cover
4. Plug 14. PTO flange
5. Copper washer 15. Bolt
6. O-ring 16. O-ring
7. Sealing washer 17. Bolt
8. Test port plug 18. Drain plug
9. Breather 19. Rear housing
10. Breather pipe 20. Front housing
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RCPH10TLB021GAL 1
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Power Shuttle transmission - Hydraulic schema - Two Wheel Drive

Schematic
RCPH11TLB001HAL 1
(1) Park Brake Solenoid (16) Differential Lock Solenoid

(2) SAHR Park Brake (17) Flow Divider
(3) Torque Converter Relief Valve (18) Regulated Clutch Pressure
(4) Torque Converter (19) Modulation Spool and Piston (Regulates
Clutch Pressure)
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(5) Oil Cooler (20) Lubrication To Bearings and Clutch Packs

(6) Oil Temperature Sender (Oil Cooler) (21) Reverse Clutch
(7) Lubrication Pressure (22) Reverse Clutch Pressure
(8) Lubrication to Synchronizers and Gears (23) Reverse Clutch Solenoid
(9) Forward Clutch (24) Control Valve Assembly
(10) Forward Clutch Pressure (25) Pressure Regulator
(11) Forward Clutch Solenoid (26) Filter (Full flow with by-pass, 15 micron)
(12) Forward/ Reverse Shuttle Spool (Directs (27) Cold Oil By-Pass
flow to forward/reverse clutches)
(13) Torque Converter Inlet Pressure (28) Supply Pump
(14) Modulator Circuit (Pressure modulation (29) Strainer
for Forward/Reverse)
(15) To Differential Lock (Rear axle)
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Power Shuttle transmission - Hydraulic schema - Four Wheel Drive

Schematic
RCPH11TLB002HAL 1
(1) Park Brake Solenoid (18) Regulated Clutch Pressure

(2) SAHR Park Brake (19) Modulation Spool and Picton (Regulates
clutch pressure)
(3) Torque Converter Relief Valve (20) Lubrication To Bearings And Clutch Packs
(4) Torque Converter (21) Reverse Clutch
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(5) Oil Cooler (22) Reverse Clutch Pressure

(6) Oil Temperature Sender (Oil Cooler) (23) Reverse Clutch Solenoid
(7) Lubrication Pressure (24) Control Valve Assembly
(8) Lubrication To Synchronizers and Gears (25) Pressure Regulator
(9) Forward Clutch (26) Filter (Full flow with by-pass, 15 micron)
(10) Forward Clutch Pressure (27) Cold Oil By-Pass
(11) Forward Clutch Solenoid (28) Supply Pump
(12) Forward/ Reverse Shuttle Spool (Directs (29) Strainer
flow to Forward/ Reverse clutches)
(13) Torque Converter Inlet Pressure (30) Check Valve
(14) Modulation Circuit (Pressure modulation (31) Supply Pump Pressure For Four Wheel
for Forward/ Reverse) Drive
(15) To Differential Lock (Rear axle) (32) Four Wheel Drive Selector Valve
(16) Differential Lock Solenoid (33) Four Wheel Drive Clutch (Spring applied,
hydraulic release)
(17) Flow Divider
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Power Shuttle transmission - Remove

Prior operation:
Prior operation:
Rear wheel - Remove (44.520)
Prior operation:
Fuel tank - Remove (10.216)
Prior operation:
Hydraulic Pump removal
1. Position machine on a flat surface high enough to

allow transmission removal.
2. Remove front drive shaft guard.
RCPH11TLB001AAL 3 RCPH11TLB002AAL 4
3. Remove front drive shaft hardware.
RCPH11TLB003AAL 5
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4. Remove shaft from yoke.
RCPH11TLB004AAL 6
5. Remove front drive shaft.
RCPH11TLB005AAL 7
6. Remove plug and drain transmission oil. Install plug

into transmission after all of the oil has drained.
RCPH11TLB006AAL 8
7. Identify, tag and disconnect the transmission cooler

lines.
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8. Disconnect the transmission control valve connec-

tion.
RCPH11TLB009AAL 11
9. Remove control valve connection bracket.
RCPH11TLB010AAL 12
10. Disconnect the brake return line.
RCPH11TLB011AAL 13
11. Disconnect brake supply line.
RCPH11TLB012AAL 14
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12. Remove oil level tube.
RCPH11TLB013AAL 15
13. Disconnect oil the temperature sensor.
RCPH11TLB014AAL 16
14. Disconnect blue wire at switch (left hand rear of

transmission).
RCPH11TLB015AAL 17
15. Disconnect black and white wire at switch (left hand

rear top of transmission).
RCPH11TLB016AAL 18
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16. Disconnect the differential lock line.
RCPH11TLB017AAL 19
17. Plug and cap all open ports.
RCPH11TLB018AAL 20
18. Disconnect starter ground and positive battery con-

nections.
RCPH11TLB051AAM 21
19. Remove the starter.
RCPH11TLB052AAM 22
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20. Disconnect the ignition connection.
RCPH11TLB053AAM 23
21. Remove the access cover.
RCPH11TLB019AAL 24
22. Rotate engine to access flywheel hardware. Use tool

380000988 to rotate the engine.
RCPH11TLB062AAM 25
23. Rotate the engine to remove the flywheel to flex plate

hardware.
RCPH11TLB055AAM 26
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24. Use an appropriate lifting device to support engine.
RCPH11TLB020AAL 27
25. Support the transmission.
RCPH11TLB021AAL 28
26. Remove the engine to transmission hardware.
RCPH11TLB058AAM 29
27. Remove the right hand and left hand transmission

mount hardware.
RCPH11TLB022AAL 30
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28. Disconnect hydraulic reservoir hoses.
RCPH11TLB023AAL 31
29. Carefully remove the transmission.
RCPH11TLB024AAL 32
Next operation:
Power Shuttle transmission - Install (21.112)
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Power Shuttle transmission - Install

1. Move the transmission under the machine and raise
it into place.
RCPH11TLB024AAL 1
2. Connect the hydraulic reservoir hoses.
RCPH11TLB023AAL 2
3. Install the right hand and left hand transmission

mount hardware.
RCPH11TLB022AAL 3
4. Remove the transmission support.
RCPH11TLB021AAL 4
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5. Remove engine supports.
RCPH11TLB020AAL 5
6. Remove the access cover.
RCPH11TLB019AAL 6
7. Rotate the engine to access the flywheel mounting

holes. Use the 380000988 Turning Tool to rotate the
engine.
RCPH11TLB062AAM 7
8. Install the flywheel flex plate hardware.
RCPH11TLB055AAM 8
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9. Reconnect the ignition connection on the starter.
RCPH11TLB053AAM 9
10. Reinstall starter.
RCPH11TLB052AAM 10
11. Connect the starter ground and positive battery con-

nections.
RCPH11TLB051AAM 11
12. Connect the differential lock line.
RCPH11TLB017AAL 12
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13. Connect the black and white wire at the switch (left
hand rear top of transmission).
RCPH11TLB016AAL 13
14. Connect the blue wire at the switch (left hand rear of
transmission).
RCPH11TLB015AAL 14
15. Connect the oil temperature sensor.
RCPH11TLB014AAL 15
16. Install the oil level tube.
RCPH11TLB013AAL 16
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17. Connect brake supply line.
RCPH11TLB012AAL 17
18. Connect the brake return line.
RCPH11TLB011AAL 18
19. Install control valve connection bracket.
RCPH11TLB010AAL 19
20. Reconnect the transmission control valve connec-

tion.
RCPH11TLB009AAL 20
21. Reconnect the transmission cooler lines.
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22. Install front drive shaft.
RCPH11TLB005AAL 23
23. Install shaft to the yoke.
RCPH11TLB004AAL 24
24. Install front drive shaft hardware.
RCPH11TLB003AAL 25
25. Install front drive shaft guard.
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26. Install wheels. Remove supports and lower machine.
NOTICE: Before staring the engine do the following

27. Make sure the transmission drain plug has been in-
stalled and tightened.
28. Fill the transmission, see Capacities ()
NOTE: If removed, install the rear wheels.

29. Remove the stands from under the machine and
lower the machine to the floor.
30. With the machine parked on level ground and the
engine running at low idle, check the transmission
oil level. The oil level must be between the ADD and
the FULL marks on the dipstick. If the oil level is at
the ADD mark, add oil as required until the oil level
is at the FULL mark.
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Power Shuttle transmission - Check Checking Supply Pump

Pressure (4WD Only)
NOTE: See Power Shuttle transmission - Tool connection Two Wheel Drive Port Identification (21.112) for port
identification.
NOTE: Two wheel drive machines can only be tested by performing a flow meter test.
1. Engage the parking brake.
2. Start the engine. The oil should be at normal operat-
ing temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 10 (A),
see Power Shuttle transmission - Tool connec-
tion Four Wheel Drive Port Identification (21.112).
4. Monitor the gauge and record the values for low idle,
see Power Shuttle transmission - Pressure test –
4 Wheel Drive, Test One — Engine at Idle 900 to
1100 rpm (21.112).
5. Monitor the gauge and record the values for full throt-
tle, see Power Shuttle transmission - Pressure
test — 4 Wheel Drive, Test Two — Engine at 2200
rpm (21.112).
RCPH11TLB014BAL 1
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Power Shuttle transmission - Test - Checking Converter In Pressure

NOTE: See Power Shuttle transmission - Tool connection Two Wheel Drive Port Identification (21.112) or Power
Shuttle transmission - Tool connection Four Wheel Drive Port Identification (21.112) for test port locations.
ing temperatures.
3. Connect a 14 bar (200 psi) to test port 6 (A) for 2WD
or 4WD machines.
4. Place transmission controls in neutral.
1100 rpm (21.112) or Power Shuttle transmission -
Pressure test – 4 Wheel Drive, Test One — Engine
at Idle 900 to 1100 rpm (21.112).
6. Monitor the gauge and record the values for full
throttle, see Power Shuttle transmission - Pres-
sure test — 2 Wheel Drive, Test Two — Engine at
2200 rpm (21.112) or Power Shuttle transmission
- Pressure test — 4 Wheel Drive, Test Two —
Engine at 2200 rpm (21.112).
RCPH11TLB015BAL 1
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Power Shuttle transmission - Test - Checking Regulated Clutch

Pressure
ing temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 3 (A).
4. Move the direction control lever to forward.
at Idle 900 to 1100 rpm (21.112).
Engine at 2200 rpm (21.112).
RCPH11TLB016BAL 1
7. Repeat steps 5 and 6 with the control lever in re-

verse.
NOTE: Forward and reverse clutch pressure can be recorded separately using test port 5 (C) for Forward and test
port 4 (B) for Reverse.
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Power Shuttle transmission - Test Checking Supply Pump Flow

and Relief Pressure
CAS-40033 Transmission Tool Kit
CAS-2011 Adapter with CAS-2383 Adapter Tube
OEM-1239 (CAS-10280) Flowmeter
1. Verify that all test equipment is clean.
ing temperatures.
4. Connect flowmeter and adapter to the transmission
filter base at test port 1 (A) and test port 2 (B). Open
the load valve on the flowmeter.
5. Move the transmission control into neutral.
at Idle 900 to 1100 rpm (21.112).
Engine at 2200 rpm (21.112).
8. At full throttle, close the load valve until the flow
drops. Read and record the pressure at which the
flow dropped.
RCPH11TLB017BAL 1
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Power Shuttle transmission - Test - Checking Converter Out

Pressure
ing temperatures.
3. Connect a 20 bar (200 psi) to the service tee on test
port 8 (A).
4. Place the transmission in the neutral position.
at Idle 900 to 1100 rpm (21.112).
Engine at 2200 rpm (21.112).
RCPH11TLB018BAL 1
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Power Shuttle transmission - Test Checking Lubrication Pressure

ing temperatures.
3. Connect a 42 bar (600 psi) gauge to test port 9 (A).
4. Place the transmission in neutral.
at Idle 900 to 1100 rpm (21.112).
Engine at 2200 rpm (21.112).
RCPH11TLB019BAL 1
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Power Shuttle transmission - Test - Checking Differential Lock Valve

CAS-1804 Pressure Test Kit
2. Place the transmission in neutral.
ing temperatures.
4. Connect a pressure test fitting and a 42 bar (600 psi)
gauge to test port 7 (A).
5. With the transmission shift lever in Neutral, put the
directional control lever in Forward or Reverse.
6. Run the engine at 2200 RPM.
7. Press and hold the differential lock switch located in
the loader control valve.
at Idle 900 to 1100 rpm (21.112).
Engine at 2200 rpm (21.112).
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Power Shuttle transmission - Pressure test – 2 Wheel Drive, Test

One - Engine at Idle 900 to 1100 rpm
NOTE: All specifications shown were taken from a sampling of new peoduction machines with less than 20 engine
hours, your figures may differ slightly.
Test Port Item Specifications — 4 wheel Actual

Drive
1 and 2 Supply Pump Flow 27 to 28 L/min at 1379 kPa
14 bar at 49° C (7.02 to 7.28
gpm at 200psi at 120° F)
1 and 2 Cold Oil By-Pass 2875 kPa to 3137 kPa
29.3 bar to 32.0 bar at 49° C
(417 to 455 psi I at 120° F)
7 Differential Lock 1262 to 1317 kPa,
Pressure (FNR must 12.7 to 13.4 bar (183 to 191
be in forward or reverse psi)
Forward
10 Pump Supply Pressure 1393 to 1427 kPa
14.2 to 14.6 bar (202 to 207
kPa)
4 Regulated Clutch 1276 to 1317 kPa
Pressure 13.0 to 13.4 bar (185 to 191
psi)
6 Torque Converter IN 545 to 607 kPa
5.6 to 6.2 bar (79 to 88 psi)
8 Torque Converter OUT 393 to 414 kPa
4.0 to 4.2 bar (57 to 60 psi)
9 Lubrication Pressure 269 to 283 kPa
2.7 to 2.9 bar (39 to 42 psi)
Neutral
7.0 to 17.7 bar (194 to 202 psi)
5.3 to 5.9 bar (75 to 84 psi)
4.2 to 4.4 bar (60 to 62 psi)
3.4 to 3.7 bar (51 to 53 psi)
Reverse
14.2 to 14.6 psi (203 to 208 psi)
psi)
6 Torque Converted IN 517 to 565 kPa
5.3 to 5.8 bar (75 to 82 psi)
3.4 to 3.5 bar (48 to 50 psi)
2.2 to 2.3 bar (31 to 33 psi)
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Power Shuttle transmission - Pressure test - 2 Wheel Drive, Test

Two - Engine at 2200 rpm
Drive
1 and 2 Supply Pump Flow 62 to 70L/min at 1379 kPa
14 bar at 49° C (16.3 to 18.5
gpm at 200 psi at 120° F)
30.9 bar to 33.7 bar at 49° C
(440 to 480 psi I at 120° F)
Forward
16.2 to 16.9 bar (230 to 240
kPa)
psi)
8.4 to 9.8 bar (120 to 140 psi)
4.4 to 4.6 bar (63 to 65 psi)
3.0 to 3.1bar (42 to 44 psi)
Neutral
8.8 to 9.8 bar (125 to 140psi)
6 Torque Converter IN 724 to 862kPa
7.4 to 8.8 bar (105 to 125 psi)
4.9 to 5.3 bar (70 to 73 psi)
4.2 to 4.4 bar (60 to 63 psi)
Reverse
15.9 to 16.6 psi (226 to 236 psi)
psi)
8.4 to 9.8 bar (120 to 140 psi)
4.0 to 4.2 bar (57 to 60 psi)
2.5 to 2.6 bar (35 to 37 psi)
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Power Shuttle transmission - Tool connection Two Wheel Drive

Port Identification
RCPH11TLB002GAL 1
1. Flow meter adapter from charge pump to flow meter (Use CAS-2011). Connect the CAS-1029 Flow
meter or equivalent. Pump supply pressure on 2 Wheel Drive units can only be taken with a flow
meter connected to ports 1 and 2.
2. Return from flow meter to transmission (CAS-2383).
3. Regulated clutch pressure, common to forward and reverse. Use CAS-2745 and CAS-2746
4. Regulated reverse clutch pressure. Use CAS-2745 and CAS-2746
5. Regulated forward clutch pressure. Use CAS-2745 and CAS–2746
6. Torque Converter IN pressure. Use CAS-2745 and CAS-2746
7. Differential lock pressure. Use CAS-2744
8. Converter out to cooler. Use CAS-2747
9. Lubrication pressure, common to converter return. Use CAS-2745 and CAS-2746 or use CAS-2747
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Power Shuttle transmission - Tool connection - Pressure Test

Ports, Two Wheel Drive
RCPH11TLB004GAL 1
(1) Reverse Clutch Pressure (3) Regulated Clutch Pressure

(2) Forward Clutch Pressure (4) Torque Converter Pressure
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Power Shuttle transmission - Tool connection Pressure Test Ports

4 Wheel Drive
RCPH11TLB005GAL 1
(1) Supply Pump Pressure, Four Wheel Drive (4) Regulated Clutch Pressure
Only
(2) Reverse Clutch Pressure (5) Torque Converter Pressure
(3) Forward Clutch Pressure
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Power Shuttle transmission - Tool connection Four Wheel Drive

Port Identification
RCPH11TLB003GAL 1
1. Flow meter adapter from charge pump to flow meter (Use CAS-2011). Connect the CAS-1029 Flow
meter or equivalent.
2. Return from flow meter to transmission (CAS-2383).
3. Regulated clutch pressure, common to forward and reverse. Use CAS-2745 and CAS-2746
4. Regulated reverse clutch pressure. Use CAS-2745 and CAS-2746
5. Regulated forward clutch pressure. Use CAS-2745 and CAS–2746
6. Torque Converter IN pressure. Use CAS-2745 and CAS-2746
7. Differential lock pressure. Use CAS-2744
8. Converter out to cooler. Use CAS-2747
9. Lubrication pressure, common to converter return. Use CAS-2745 and CAS-2746 or use CAS-2747
10. Pump supply pressure, 4 wheel drive only. Use CAS-2745 and CAS-2746
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Power Shuttle transmission - Pressure test – 4 Wheel Drive, Test

One - Engine at Idle 900 to 1100 rpm
NOTE: All specifications shown were taken from a sampling of new production machines with less than 20 engine
hours, your figures may differ slightly.

Drive
1 and 2 Supply Pump Flow 27 to 28 L/min at 1379 kPa
14 bar at 49° C (7.02 to 7.28
gpm at 200psi at 120° F)
29.3 bar to 32.0 bar at 49° C
(417 to 455 psi I at 120° F)
Forward
14.2 to 14.6 bar (202 to 207
kPa)
psi)
5.6 to 6.2 bar (79 to 88 psi)
4.0 to 4.2 bar (57 to 60 psi)
2.7 to 2.9 bar (39 to 42 psi)
Neutral
7.0 to 17.7 bar (194 to 202 psi)
5.3 to 5.9 bar (75 to 84 psi)
4.2 to 4.4 bar (60 to 62 psi)
3.4 to 3.7 bar (51 to 53 psi)
Reverse
14.2 to 14.6 psi (203 to 208 psi)
psi)
5.3 to 5.8 bar (75 to 82 psi)
3.4 to 3.5 bar (48 to 50 psi)
2.2 to 2.3 bar (31 to 33 psi)
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Power Shuttle transmission - Pressure test - 4 Wheel Drive, Test

Two - Engine at 2200 rpm
Drive
1 and 2 Supply Pump Flow 62 to 70L/min at 1379 kPa
14 bar at 49° C (16.3 to 18.5
gpm at 200 psi at 120° F)
30.9 bar to 33.7 bar at 49° C
(440 to 480 psi I at 120° F)
Forward
16.2 to 16.9 bar (230 to 240
kPa)
psi)
8.4 to 9.8 bar (120 to 140 psi)
4.4 to 4.6 bar (63 to 65 psi)
3.0 to 3.1bar (42 to 44 psi)
Neutral
14.4 to 14.9 bar (205 to 212
psi)
6 Torque Converter IN 724 to 862kPa
7.4 to 8.8 bar (105 to 125 psi)
4.9 to 5.3 bar (70 to 73 psi)
4.2 to 4.4 bar (60 to 63 psi)
Reverse
15.9 to 16.6 psi (226 to 236 psi)
psi)
8.4 to 9.8 bar (120 to 140 psi)
4.0 to 4.2 bar (57 to 60 psi)
2.5 to 2.6 bar (35 to 37 psi)
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Transmission housing - Disassemble

NOTE: Some photos may not represent your transmission, the procedures are the same.
1. Fasten the rear housing to acceptable support equip-
ment . It is recommended that you use equipment
that will let you rotate the transmission.
RCPH10TLB689AAL 1
2. Remove the drain plug and drain the oil from the
transmission.
RCPH10TLB690AAL 2
NOTE: The four-wheel drive transmission is shown. On two-wheel drive transmissions, the drain plug is at the rear
of the transmission.
3. Remove the two cap screws that fasten the cover for
the oil screen. Remove the cover.
RCPH10TLB693AAL 3
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4. Remove the oil screen and the O-ring.
RCPH10TLB695AAL 4
NOTE: Steps 8 through 10 are for four-wheel drive transmissions only. If you are working on a two-wheel drive trans-
mission, go to step 11.
5. Remove the oil filter.
RCPH10TLB698AAL 5
6. DO NOT remove the plug unless the plug is leaking.

The plug is sealed with Loctite 542 or Loctite 262
and is difficult to remove. If removal is necessary,
clean all oil from the threads and apply Loctite 542
or Loctite 262 (red) before installation.
RCPH10TLB703AAL 6
7. Remove the fitting for the oil filter.
RCPH10TLB699AAL 7
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8. Remove the spool.
RCPH10TLB701AAL 8
9. Remove the spring.
RCPH10TLB702AAL 9
10. Use a blind hole puller to remove the four-wheel drive

priority valve.
RCPH10TLB907AAL 10
NOTE: The four-wheel drive priority valve is adjusted at the factory. DO NOT try to disassemble or adjust the four-
wheel drive priority valve. If any of the parts are damaged, use a new four-wheel drive priority valve.
11. Remove the dipstick.
RCPH10TLB908AAL 11
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12. Remove the dipstick tube.
RCPH10TLB909AAL 12
13. Remove the fitting for the dipstick tube.
RCPH10TLB808AAL 13
14. Remove the bolts that fasten the transmission control

valve to the front housing.
RCPH10TLB847AAL 14
15. Remove the transmission control valve and the gas-

ket.
16. Remove the three bolts that fasten the four-wheel
drive valve to the front housing.
RCPH10TLB848AAL 15
17. Remove the four-wheel drive valve and the gasket.
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18. Remove the seven bolts that fasten the pump mount
to the rear housing.
RCPH10TLB849AAL 16
19. Remove the pump mount housing.
RCPH10TLB850AAL 17
20. Use a plastic mallet and tap the through shaft out of
the transmission rear housing.
RCPH10TLB851AAL 18
21. Pull the shaft from the transmission.
RCPH10TLB852AAL 19
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22. Remove the seal from the shaft.
RCPH10TLB814AAL 20
23. Remove the snap ring from the pump shaft.
RCPH10TLB813AAL 21
24. Use a suitable driver and remove the bearing from

the pump drive shaft.
RCPH10TLB812AAL 22
25. Remove the pressure sensor switch from the brake

housing.
RCPH10TLB853AAL 23
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26. Remove the solenoid from the brake housing.
RCPH10TLB854AAL 24
27. Make sure the orifice remains in the brake housing.
RCPH10TLB855AAL 25
28. Remove the three Allen head bolts that fasten the
shifter housing to the rear cover. Remove the shifter
assembly and the O-ring.
RCPH10TLB856AAL 26
29. Remove the bolt and the output flange.
RCPH10TLB857AAL 27
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30. Remove the output flange.
RCPH10TLB858AAL 28
31. Remove three of the parking brake cover bolts.

Loosen the remaining three bolts evenly one turn
at a time to relieve spring pressure in the brake
housing.
RCPH10TLB859AAL 29
NOTE: Housing is under spring pressure, failure to follow instructions will result in serious injury and damage to
equipment.
32. Remove the brake discs from the brake housing.
RCPH10TLB859AAL 30
33. Remove the brake disc flange from the output shaft.
RCPH10TLB860AAL 31
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34. Remove the rear cover mounting bolts.
RCPH10TLB861AAL 32
35. At the three prying points, use pry bars and loosen
the rear cover from the transmission.
RCPH10TLB864AAL 33
36. Remove the rear cover from the transmission.
RCPH10TLB865AAL 34
37. Remove the seal from the rear cover.

38. Use a punch to remove the pins that fasten the shift
collars to the shift rods.
RCPH10TLB723AAL 35
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39. Remove the shift collars from the shift rods.
RCPH10TLB725AAL 36
40. Remove the two Allen head bolts that hold the plate
between the two shift rods.
RCPH10TLB726AAL 37
41. Remove the plate.
RCPH10TLB728AAL 38
42. Remove the two shift interlock balls from the groove
between the two shift rods.
RCPH10TLB729AAL 39
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43. Remove one of the detent plugs from the right-hand

side of the rear housing.
RCPH10TLB730AAL 40
44. Remove the detent spring.
RCPH10TLB731AAL 41
45. Remove the detent ball.
RCPH10TLB049ABL 42
46. Repeat steps 43 through 45 to remove the other de-

tent plug, spring, and ball.
NOTE: Rotate the transmission in the stand so the shafts will not fall out when the snap ring is removed.
47. Push the secondary shaft to the rear so that there is
clearance between the snap ring and the rear hous-
ing. Remove the snap ring.
RCPH10TLB732AAL 43
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NOTE: If the bearing is not very tight on the secondary shaft, parts could fall from the secondary shaft when you
remove the secondary shaft from the rear housing. To prevent this, you can install a hose clamp on the output end of
the secondary shaft. This will keep the bearing in position during removal of the secondary shaft.
48. Remove all of the housing bolts that are fastened
from the rear housing to the front housing. There
are 13 of these bolts on the four-wheel drive and 14
on the two-wheel drive. On the two-wheel drive, two
of the bolts are longer than the others. Record the
locations of these two.
RCPH10TLB704AAL 44
49. Rotate the transmission so that the front housing is

up. On four-wheel drive transmissions only, there are
three bolts fastened from the front housing to the rear
housing. Remove these bolts.
RCPH10TLB717AAL 45
NOTE: Steps 50 through 57 are for four-wheel drive transmissions only. If you are working on a two-wheel drive
transmission, go to step 58.
50. Install two bolts in the four-wheel drive flange as
shown. Use a pry bar between the two bolts to hold
the four-wheel drive flange while you remove the bolt
from the four-wheel drive shaft.
RCPH10TLB906AAL 46
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51. Remove the washer.
RCPH10TLB705AAL 47
52. Remove the four-wheel drive flange.
RCPH10TLB706AAL 48
53. Remove the O-ring from the four-wheel drive flange.
RCPH10TLB707AAL 49
54. Remove the three bolts that fasten the cover to the
front housing.
RCPH10TLB708AAL 50
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55. Remove the cover.
RCPH10TLB710AAL 51
56. Remove the O-ring from the cover.
RCPH10TLB711AAL 52
57. Remove the seal from the cover.
RCPH10TLB020ABL 53
58. Make a mark across the joint between the oil pump
and the torque converter housing so that the oil pump
can be aligned the same way during installation.
RCPH10TLB866AAL 54
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59. Remove the six bolts that fasten the oil pump in po-
sition.
RCPH10TLB867AAL 55
60. Use two pry bars to lift the oil pump evenly until the
oil pump can be removed.
RCPH10TLB713AAL 56
61. Remove the oil pump.
RCPH10TLB714AAL 57
62. Pull up the input shaft to get clearance as you release

the snap ring.
RCPH10TLB715AAL 58
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63. Remove the snap ring.
RCPH10TLB716AAL 59
64. Fasten acceptable lifting equipment to the front hous-

ing as shown. Use pry bars at both ends of the hous-
ings to separate the front housing from the rear hous-
ing.
RCPH10TLB718AAL 60
65. As you lift the front housing, continue to use the pry
bar to make sure that the front housing comes up
evenly. Also, it will probably be necessary to hit the
end of the four-wheel drive shaft, if so equipped, and
the end of the input shaft with a soft hammer so that
the two shafts come down out of the front housing
and stay with the rear housing.
RCPH10TLB910AAL 61
NOTE: The bearings in steps 66 and 67 are a close slip fit. If a bearing is difficult to remove, the bearing is probably
not straight in the bore or on the shaft. Push the bearing back into the installed position and try again.
66. The bearing for the primary shaft and the bearing for
the secondary shaft can stay with either the shafts or
the front housing. Remove the two bearings.
RCPH10TLB720AAL 62
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67. On machines with four-wheel drive, remove the four-

wheel drive shaft bearing from the front housing.
RCPH10TLB911AAL 63
68. Remove the tube from the front housing only if the
tube is damaged or leaking.
RCPH10TLB027ABL 64
69. Remove the three O-rings from the flange of the rear
housing.
RCPH10TLB920AAL 65
70. On machines with four-wheel drive, remove the four-

wheel drive shaft.
RCPH10TLB720AAL 66
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71. Remove the input shaft and the reverse shaft to-
gether.
RCPH10TLB921AAL 67
NOTE: Make a mark on the top end of the reverse shaft so that you can install the reverse shaft with the same end
up during assembly.
72. Rotate the rear housing so that the open side is up.
Connect acceptable lifting equipment to the top gear
on the secondary shaft.
RCPH10TLB912AAL 68
73. Use the lifting equipment to begin lifting the sec-

ondary shaft while you use your hands to lift the pri-
mary shaft. At the same time, move the primary
shaft back and forth to keep the primary shaft mov-
ing freely. It can be necessary to tap the ends of the
shift rods (from below the rear housing) so that the
shift rod and fork assemblies continue to move freely.
When the primary shaft is free of the rear housing
and the secondary shaft, remove the primary shaft.
RCPH10TLB913AAL 69
74. Continue to lift the secondary shaft until you can

move the secondary shaft out of the shift forks. Then
remove the secondary shaft.
RCPH10TLB914AAL 70
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75. Remove the shift rod and fork assembly for first and
second gear from the rear housing.
RCPH10TLB915AAL 71
76. Remove the shift rod and fork assembly for third and
fourth gear from the rear housing. Remember that
this assembly was installed in the bore nearer the
top of the rear housing.
RCPH10TLB916AAL 72
NOTE: Steps 77 and 78 are for four-wheel drive transmissions only. If you are working on a two-wheel drive trans-
77. Remove the four-wheel drive clutch gear.
RCPH10TLB733AAL 73
78. Remove the bearing.
RCPH10TLB917AAL 74
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79. It is not necessary to remove the test port plugs (1),

the breather (2), or the temperature sender (3) from
the rear housing unless these parts are leaking or
damaged.
RCPH10TLB918AAL 75
80. Inspect the input shaft bore in the rear housing. If

there are grooves from the sealing rings, you must
use a new rear housing. Remove any sharp edges
at the ends of the input shaft bore and at the oil dis-
tribution holes.
81. Remove the four-wheel drive clutch tube (four-wheel
drive machines only) from the front housing only if
the front housing must be replaced or if the tube is
leaking or damaged.
RCPH10TLB023ABL 76
82. Remove the three Allen head bolts that fasten the
valve plate to the front housing.
RCPH10TLB025ABL 77
83. Remove the valve plate from the front housing.
RCPH10TLB024ABL 78
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84. Remove the gasket.
RCPH10TLB026ABL 79
Next operation:
Transmission drive and driven shafts - Disassemble (21.154)
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Transmission housing - Disassemble - Shifter housing

1. Use side cutters as shown to release the catch on
the band that fastens the boot to the shifter housing.
Remove the band.
RCPH10TLB012ABL 1
2. Remove the boot from the shifter housing.
RCPH10TLB013ABL 2
3. Remove the two pins (one on either side of the shifter

housing). Use a screwdriver to lift each pin as shown
until you can reach the pin with your fingers. Then
pull the pin out.
RCPH10TLB013ABL 3
4. Remove the snap ring from the shift lever.
RCPH10TLB016ABL 4
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5. Remove the bushing from the shift lever.
RCPH10TLB019ABL 5
RCPH10TLB018ABL 6
7. Remove the shift lever from the shifter housing.
RCPH10TLB017ABL 7
Next operation:
Transmission housing - Disassemble (21.112)
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Transmission housing - Disassemble - Shift rods and shift forks

1. If disassembly is required, remove the roll pins and
separate the shift forks from the shift rods. Make sure
that you remember how the parts are assembled and
which parts go together. The forks are the only parts
that are not interchangeable. Inspect all parts for
burrs and excessive wear. Assembly is the reverse
of disassembly.
RCPH10TLB944AAL 1
Next operation:
Transmission housing - Assemble (21.112)
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Transmission housing - Assemble - Shifter housing

1. Apply lithium grease to the ball of the shift lever. In-
stall the shift lever in the shifter housing.
RCPH10TLB017ABL 1
2. The correct alignment of the shift lever and the shifter

housing is shown above. The slot (1) in the shift lever
must be toward the flat side (2) of the flange on the
shifter housing. The slots (3) on each side of the shift
lever must be aligned with the holes (4) in each side
of the shifter housing.
RCPH10TLB021ABL 2
3. Install the spring.
RCPH10TLB018ABL 3
4. Install the bushing.
RCPH10TLB019ABL 4
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5. Put the snap ring on the shift lever. Use a deep

well socket to push the snap ring into the snap ring
groove.
RCPH10TLB015ABL 5
6. Install the pins through the holes in the shifter hous-

ing so that the pins engage the slots in the shift lever.
RCPH10TLB013ABL 6
7. Install the boot so that the end of the boot fits over
the ends of the pins. Be careful so that the pins do
not fall out during this step.
RCPH10TLB013ABL 7
8. Install the band or clamp on the boot. Use the side

cutters to engage the catch on the band.
RCPH10TLB012ABL 8
Next operation:
Transmission control valve - Disassemble (21.134)
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Transmission housing - Assemble - Transmission housing

1. If the four-wheel drive clutch tube (four-wheel drive
machine only) was removed from the front housing,
install the four-wheel drive clutch tube. Tighten the
fittings to a torque of 40 Nm (265 pound-inches).
RCPH10TLB023ABL 1
2. Install plugs (foam ear plugs work well) in the three oil
passages in the edge of the rear housing. Scrape all
sealing material from the sealing surface of the rear
housing. Prepare the sealing surface by rubbing with
a 3M Scotch-Brite fiber pad or equivalent. DO NOT
use steel wool or anything that can leave material
on the sealing surface. Flush the rear housing with
solvent.
RCPH10TLB028ABL 2
3. Install plugs (foam ear plugs work well) in the three

oil passages in the edge of the front housing. (The
plugs have not been installed in the picture above.)
Scrape all sealing material from the sealing surface
of the front housing. Prepare the sealing surface by
rubbing with a 3M Scotch-Brite fiber pad or equiv-
alent. DO NOT use steel wool or anything that can
leave material on the sealing surface. Flush the front
housing with solvent.
RCPH10TLB023ABL 3
4. Install the gasket for the valve plate on the front hous-
ing.
RCPH10TLB026ABL 4
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5. Put the valve plate into position.
RCPH10TLB024ABL 5
6. Install the three Allen head bolts to fasten the valve

plate to the front housing. Tighten the Allen head
bolts to a torque of 23 Nm (204 pound-inches).
RCPH10TLB025ABL 6
7. If the test port plugs (1), the breather (2), and the
temperature sender (3) were removed from the rear
housing, install these parts. Tighten the test port
plugs (1) to a torque of 23 Nm (204 pound-inches).
RCPH10TLB918AAL 7
8. Put the bearing for the four-wheel drive shaft into
position in the rear housing.
RCPH10TLB917AAL 8
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9. Install the four-wheel drive clutch gear so that the

side with the lugs is up.
RCPH10TLB733AAL 9
10. Connect acceptable lifting equipment to the top gear

on the secondary shaft. Lift the secondary shaft over
the rear housing. Engage the shift forks with the syn-
chronizers as shown. Begin to lower the assembly
into the rear housing.
RCPH10TLB029ABL 10
11. As you lower the assembly into the rear housing, also
begin to install the primary shaft so that the gears on
the primary shaft go into mesh with the gears on the
secondary shaft. Continue to lower the parts, making
sure that each part goes into the correct bore in the
rear housing. (Remember that the shift rod and fork
assembly for third and fourth gear goes into the bore
nearer the top of the rear housing). When all of the
parts are in position, disconnect the lifting equipment.
RCPH10TLB913AAL 11
12. Push the secondary shaft toward the rear of the rear
housing so that there is clearance between the snap
ring groove and the rear housing. Install the snap
ring.
RCPH10TLB732AAL 12
NOTE: In steps 13 through 15, the photos show the upper detent parts already installed. It is necessary for you to
install both the upper and lower detent parts according to the instructions in the procedure. Make sure that you start
with both shift rods in the NEUTRAL position.
47365539 08/07/2012
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13. Install the lower detent ball.
RCPH10TLB049ABL 13
14. Install the lower detent spring.
RCPH10TLB731AAL 14
15. Install the copper washer on the detent plug. Install

the lower detent plug. Tighten the lower detent plug
to a torque of 80 Nm (59 pound-feet).
RCPH10TLB730AAL 15
16. Repeat steps 13 through 15 to install the upper de-

tent ball, spring, copper washer, and plug.
17. Install the two detent balls in the groove between the
two shift rods.
RCPH10TLB729AAL 16
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18. Install the plate over the two detent balls.
RCPH10TLB728AAL 17
19. Apply Loctite 542 or Super bond 321 to the threads

of the two Allen head bolts. Install the two Allen head
bolts to fasten the plate in position. Tighten the two
Allen head bolts to a torque of 50 Nm (37 pound-
feet).
RCPH10TLB727AAL 18
20. Install the shift collars on the shift rods.
RCPH10TLB725AAL 19
21. Install the pins to fasten the shift collars to the shift
rods.
RCPH10TLB724AAL 20
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22. Scrape all sealing material from the sealing surface

of the rear cover. Prepare the sealing surface by
rubbing with a 3M Scotch-Brite fiber pad or equiv-
alent. DO NOT use steel wool or anything that can
leave material on the sealing surface. Wipe the seal-
ing surface with Loctite Safety Solvent or equivalent.
Apply a layer of Loctite 518 or Super bond 539 to the
sealing surface.
23. Put the rear cover in position. Make sure that the
dowel is installed in the rear housing and through the
hole in the rear cover. Install the seven bolts to fasten
the rear cover to the rear housing. If necessary, tap
the rear cover with a soft faced hammer to close the
gap between the rear housing and the rear cover
before you tighten the bolts. Tighten the seven bolts
sequentially to a torque of 50 Nm (37 pound-feet).
RCPH10TLB861AAL 21
NOTE: The above photo shows the shifter installed, the shifter should not be installed at this time.
24. Install a new O-ring on the shifter assembly. Use
clean oil to lubricate the O-ring. Put the shifter as-
sembly into position on the rear cover.
RCPH10TLB722AAL 22
25. Install the three Allen head bolts to fasten the shifter
assembly to the rear cover. Tighten the three Allen
head bolts to a torque of 23 Nm (204 pound-inches).
RCPH10TLB721AAL 23
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26. If the tube was removed from the front housing, in-
stall the tube now. Tighten the hollow bolts to a
torque of 40 Nm (354 pound-inches).
RCPH10TLB027ABL 24
27. Install the input shaft and the reverse shaft together
as shown. If you are using the same reverse shaft,
make sure that you install it with the same end up as
when it was removed.
RCPH10TLB921AAL 25
28. On machines with four-wheel drive, install the four-

wheel drive shaft. Use clean transmission oil to lu-
bricate the bearing surfaces on the four-wheel drive
shaft. Make sure that the four-wheel drive shaft goes
through the four-wheel drive clutch gear, the thrust
washer, and the bearing.
RCPH10TLB719AAL 26
29. Wipe the sealing surface of the rear housing and the
front housing with Loctite Safety Solvent or equiva-
lent. Apply a layer of Loctite 518 or Super bond 529
to the sealing surface of the rear housing.
RCPH10TLB030ABL 27
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30. Remove the three plugs from the oil passages in the
rear housing (see arrows). Install three new O-rings
for the oil passages. Remove the three plugs from
the oil passages in the front housing.
RCPH10TLB920AAL 28
31. Use clean transmission oil to lubricate the bearing for

the primary shaft and the bearing for the secondary
shaft. Install the bearings.
RCPH10TLB720AAL 29
32. Install the front housing on the rear housing. Make

sure that the bearings on the shafts go straight into
the bores in the front housing. Push the front housing
all the way down on the rear housing.
RCPH10TLB718AAL 30
33. Install all of the housing bolts that fasten the rear
housing to the front housing. There are 13 of these
bolts on four-wheel drive transmissions and 14 on
two-wheel drive transmissions. Tighten the bolts
evenly until the front housing and rear housing are
together, then tighten the bolts to a torque of 50 Nm
(37 pound-feet).
RCPH10TLB704AAL 31
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34. Install the three bolts that fasten from the front hous-
ing to the rear housing. Tighten the bolts to a torque
of 50 Nm (37 pound-feet).
RCPH10TLB033ABL 32
35. Use clean transmission oil to lubricate the bearing for

the four-wheel drive shaft. Install the bearing on the
four-wheel drive shaft.
RCPH10TLB034ABL 33
36. Use the CAS-2381 special tool to install a new seal in

the cover. Push just until the seal stops moving. DO
NOT use excessive force. Fill the cavity under the
lip of the seal with high temperature wheel bearing
grease.
RCPH10TLB022ABL 34
37. Install a new O-ring on the cover. Use clean trans-

mission oil to lubricate the O-ring.
RCPH10TLB711AAL 35
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38. Install the cover in the front housing.
RCPH10TLB710AAL 36
39. Install the three bolts that fasten the cover to the front
housing. Tighten the bolts to a torque of 23 Nm (204
pound-inches).
RCPH10TLB709AAL 37
40. Install a new O-ring in the four-wheel drive flange.

Use clean transmission oil to lubricate the O-ring.
RCPH10TLB707AAL 38
41. Install the four-wheel drive flange on the four-wheel

drive shaft.
RCPH10TLB706AAL 39
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42. Install the washer.
RCPH10TLB705AAL 40
43. Install and tighten the cap screw in the four-wheel

drive shaft to a torque of 139 Nm (103 pound-feet).
RCPH10TLB906AAL 41
44. Pull the input shaft toward the front of the transmis-
sion to get clearance for the snap ring.
RCPH10TLB031ABL 42
45. Install the snap ring on the bearing.
RCPH10TLB032ABL 43
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46. It will be easier to install the oil pump if you use a

guide stud as shown above. You can make a guide
stud by cutting the head from an M8 bolt.
RCPH10TLB036ABL 44
47. Use clean transmission oil to lubricate the O-ring on

the oil pump. Install the oil pump. Make sure that the
alignment marks that you made during disassembly
are aligned.
RCPH10TLB035ABL 45
48. If you used a guide stud, remove the guide stud. In-
stall the six bolts that fasten the oil pump in posi-
tion. Tighten the bolts to a torque of 23 Nm (204
pound-inches).
RCPH10TLB712AAL 46
49. Install the hub onto the output shaft as shown.
RCPH10TLB877AAL 47
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50. Install a reaction plate first.
RCPH10TLB876AAL 48
51. Install a friction plate and a wave spring, continue to

install a reaction plate, friction plate and wave spring
until all components are installed.
RCPH10TLB875AAL 49
52. Install the back plate as shown.
RCPH10TLB874AAL 50
53. Install a new O-ring.
RCPH10TLB873AAL 51
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54. Install the brake housing.
RCPH10TLB872AAL 52
55. Install the bolts, use an alternately tightening pattern

until the brake housing is tight against the transmis-
sion. Torque the bolts to 50 Nm (37 pound feet).
RCPH10TLB871AAL 53
56. Install the flange and a new O-ring.
RCPH10TLB869AAL 54
57. Install the bolt and washer.
RCPH10TLB868AAL 55
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58. Torque bolt to 139 Nm (103 pound feet).
RCPH10TLB870AAL 56
59. Make sure the orifice is in the brake housing, install

new O-rings.
RCPH10TLB855AAL 57
60. Install the brake solenoid, torque the solenoid to 20

Nm (15 pound feet).
RCPH10TLB854AAL 58
61. Install the pressure sensor switch into the brake

housing.
RCPH10TLB853AAL 59
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62. Slide the expander/protector onto the pump drive

shaft.
RCPH10TLB842AAL 60
63. Heat the Teflon sealing ring to 80° to 100° C (176°

to 212° F). Install the Teflon sealing ring onto the
380001428 expander/protector.
RCPH10TLB843AAL 61
64. Install the 380001928 pusher over the expander/pro-

tector and slide the sealing ring until it reaches the
groove in the shaft. Remove the pusher and ex-
pander/protector from the shaft.
RCPH10TLB844AAL 62
65. Install the end of the 380001427 seal compressor

with the deep chamfer onto the shaft and over the
sealing ring. Use a back and forth twisting motion to
allow the seal compressor to slip over the top of the
sealing ring and seat the sealing ring into the groove.
Be careful not to damage the sealing ring. After the
sealing ring is seated in the groove, remove the seal
compressor from the shaft.
RCPH10TLB845AAL 63
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66. Turn the seal compressor around and slide the end
with the narrow chamfer over the shaft and over the
sealing ring. Leave the seal compressor in place for
15 minutes until the sealing ring has cooled and is
properly sized and seated in the groove. After the
sealing ring has cooled, remove the seal compressor
from the shaft.
RCPH10TLB846AAL 64
67. Install the bearing and snap ring on the pump drive
shaft, install the shaft in the rear housing.
68. Install the PTO shaft into the transmission.
RCPH10TLB850AAL 65

of the pump mount and rear cover. Prepare the sea
ling surface by rubbing with a 3M Scotch-Brite fiber
pad or equivalent. DO NOT use steel wool or any-
thing that can leave material on the sealing surface.
Wipe the sealing surface with Loctite Safety Solvent
or equivalent. Apply a layer of Loctite 518 or Super
bond 539 to the sealing surface.
70. Install the pump mount on the rear housing, torque
bolts to 50 Nm (37 pound-feet).
RCPH10TLB849AAL 66
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71. Install the fitting for the dipstick tube.
RCPH10TLB808AAL 67
72. Install the dipstick tube.
RCPH10TLB909AAL 68
73. Install the dipstick.
RCPH10TLB908AAL 69
NOTE: The following photo shows the four-wheel drive priority valve installed and is for reference for the plug only.
74. If the plug was removed, make sure that the threads
are clean and apply Loctite 543 or Loctite 262 (red)
to the threads before installation. Tighten the plug to
a torque of 40 Nm (354 pound-inches).
RCPH10TLB703AAL 70
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75. Install the four-wheel drive priority valve in the oil filter
bore.
RCPH10TLB037ABL 71
RCPH10TLB702AAL 72
77. Install the spool.
RCPH10TLB701AAL 73
78. Install the fitting for the oil filter. Tighten the fitting to
a torque of 50 Nm (37 pound-feet).
RCPH10TLB700AAL 74
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79. Use clean transmission oil to lubricate the gasket on

the oil filter. Install the oil filter.
RCPH10TLB698AAL 75
80. Install the gasket for the four-wheel drive valve.
RCPH10TLB905AAL 76
81. Put the four-wheel drive valve in position on the gas-

ket.
RCPH10TLB697AAL 77
82. Install the three bolts that fasten the four-wheel drive
valve to the front housing. Tighten the bolts to a
torque of 23 Nm (204 pound-inches).
RCPH10TLB696AAL 78
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83. Install a new O-ring on the oil screen. Use clean

transmission oil to lubricate the O-ring. Install the oil
screen and O-ring.
RCPH10TLB695AAL 79
84. Install the cover for the oil screen. Install the two
bolts that fasten the cover for the oil screen. Tighten
the bolts to a torque of 23 Nm (204 pound-inches).
RCPH10TLB694AAL 80
85. Install the gasket for the transmission control valve.

Put the transmission control valve in position on the
gasket.
RCPH10TLB692AAL 81
86. Install the bolts that fasten the transmission control

valve to the front housing. Tighten the bolts in a
pattern alternating from front to back and side to side
until all the bolts are at a torque of 23 Nm (204 pound-
inches).
RCPH10TLB691AAL 82
NOTE: The following photo shows the drain plug for four wheel drive machines.
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87. Install a new O-ring on the drain plug. Lubricate the

O-ring with clean transmission oil. Install the drain
plug. Tighten the drain plug to a torque of 80 Nm (59
pound-feet).
RCPH10TLB690AAL 83
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Power Shuttle transmission - Testing - Machine Will Not Move

N° Test Point Expected Result Other Result (Possible Cause)
1 Check Result Action
Verify the transmission oil level. Re- The oil level is correct. Go to next The transmission oil level is not cor-
fer to Power Shuttle transmission step. rect. Check for leaks. Fill the trans-
- General specification (21.112). mission oil to the proper level. Re-
Refer to Transmission Fluid Level in fer to Transmission Fluid Level in the
the Operator’s Manual. Operator’s Manual.
Check for broken universal joint or The drive shaft and universal joint The drive shaft and universal joint
drive shaft. are free from damage. Go to next are damaged. Repair as required.
step.
3 Condition Result Action
Raise the rear wheels off the ground. The drive shaft turns when the trans- The drive shaft does not turn. Check
Check mission directional control lever the electrical connections to the
Verify that the drive shaft turns when (FNR) is moved into Forward or Re- transmission. Verify that there is
the transmission directional control verse. Go to next step. power to the clutch solenoids. Check
lever (FNR) is moved into Forward or fuse F-024.
Reverse.
Check transmission pressure and The transmission pressures and
pump flow. Refer to Power Shuttle pump flow are within specifications. The transmission pressures
transmission - Pressure test – 2 and pump flow are not within
Wheel Drive, Test One — Engine specifications. Possible causes
at Idle 900 to 1100 rpm (21.112). include:
• Cold oil by-pass valve may be
stuck or damaged.
• Faulty pressure regulator.
Faulty transmission oil pump.
•
Refer to Power Shuttle trans-
mission - Check Check-
ing Supply Pump Pressure
(4WD Only) (21.112) or Power
Shuttle transmission - Test
Checking Supply Pump Flow
and Relief Pressure (21.112).
Check the converter IN pressure. The converter IN pressure is within The converter IN pressure is not
Refer to Power Shuttle transmis- specifications. Go to next step. within specifications. Check the
sion - Test — Checking Converter transmission control valve. Re-
In Pressure (21.112) pair or replace as required. Refer
to Transmission control valve -
Inspect - Transmission control
valve (21.134)
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Check the Forward and Reverse The regulated clutch pressures are The regulated clutch pressures are
solenoid valve. Refer to Power within the specified range. Go to not within the specified range. Re-
Shuttle transmission - Test — next step. fer to Forward and Reverse solenoid
Checking Regulated Clutch Pres- troubleshooting in the Service Man-
sure (21.112). ual. .
Check regulated clutch pressure at The regulated clutch pressure is
test port 3. Refer to Power Shuttle within specifications. Refer to The regulated clutch pressure is
transmission - Test — Check- Power Shuttle transmission - not within specifications. Possible
ing Regulated Clutch Pressure Pressure test – 2 Wheel Drive, causes include:
(21.112) Test One — Engine at Idle 900 • Pressure remains zero in For-
to 1100 rpm (21.112) and Power ward, Neutral and Reverse.
Shuttle transmission - Pressure Check the control valve. Re-
test — 2 Wheel Drive, Test Two fer to Transmission control
— Engine at 2200 rpm (21.112) valve - Inspect - Transmis-
OR Power Shuttle transmission sion control valve (21.134).
- Pressure test – 4 Wheel Drive,
Test One — Engine at Idle 900 • Pressure is low, check the con-
to 1100 rpm (21.112) and Power trol valve. Refer to Transmis-
Shuttle transmission - Pressure sion control valve - Inspect
test — 4 Wheel Drive, Test Two — - Transmission control valve
Engine at 2200 rpm (21.112). (21.134).
• Pressure in Forward and Re-
verse are the same. Check the
control valve. Refer to Trans-
mission control valve - In-
spect - Transmission control
valve (21.134).
• Forward and Reverse pres-
sures are different. Inspect the
individual clutch circuits. Re-
fer to Transmission control
valve - Inspect - Transmis-
sion control valve (21.134).
Power Shuttle transmission - Testing - Will Not Go Into 4WD

Check for broken universal joint or The universal joint and front drive The universal joint or front drive shaft
front drive shaft. shaft are functioning properly. Go to are in need of repair. Repair or re-
next step. place as required.
Raise the machine off of the ground. The front drive shaft turns freely The front drive shaft does not turn
All four wheels should be able to ro- when the transmission control is in when the transmission control is in
tate freely. gear but the axle does not. There is gear. Go to next step.
Check a problem in the front axle. Repair
Verify that the front and rear drive as required.
shafts turn when the transmission
directional control lever (FNR) is
moved into Forward or Reverse.
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Check the electrical connections to The solenoid is not receiving the cor-
The solenoid is receiving the cor-
the 4WD solenoid on the transmis- rect voltage Check the 4WD rocker
rect voltage and is operating prop-
sion. erly. Go to next step. switch connections. Verify the volt-
age to the switch. Check the fuse
F-017. Refer to Wire harnesses
- Electrical schematic frame 05
Powershift Transmission Inputs
(55.100).
Check the 4WD solenoid. When The solenoid is performing correctly. The solenoid is not performing cor-
power is removed from the solenoid, Inspect the front drive shaft and rectly. Repair or replace as required.
4WD is engaged. clutch engagement teeth for dam-
age. Repair or replace as required.
Power Shuttle transmission - Testing - Machine Hesitates When

Shifting Between Forward and Reverse
Check the pump supply pressure at The pressure are all within specifica- The pressures are not within specifi-
test port 10 for 4WD machines. Re- tions. Go to next step. cations. Inspect the pressure regu-
fer to Power Shuttle transmission lator. Repair or replace as required.
- Check Checking Supply Pump
Pressure (4WD Only) (21.112).
2WD machines, test the pressure
on port 1 and port 2. Refer to
Power Shuttle transmission - Test
Checking Supply Pump Flow and
Relief Pressure (21.112)
Check the regulated clutch pres- The pressures are within specifica- The pressures were not within spec-
sure at test port 3. Refer to Power tions. ifications. Inspect the modulation
Shuttle transmission - Test — spool and piston for sticking or dam-
Checking Regulated Clutch Pres- age. Inspect the input shaft sealing
sure (21.112) rings and forward and reverse clutch
piston seals. Repair or replace as re-
quired.
Power Shuttle transmission - Testing - Loss of Power

Verify that there is not a buildup of The wheel wells and drive train are There is mud and debris in the wheel
mud or foreign material on the inside free of mud and debris. Go to next well or along the drive train. Remove
of the wheel wells or along the drive step. all mud and debris. If the problem
train. still exists, go to nest step.
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Perform a stall test according to the The engine performed to specifica- The engine did not perform to speci-
instructions in Power Shuttle trans- tions during the stall test. Go to next fications during the stall test. Repair
mission - Test — Checking Regu- step. the engine as required.
lated Clutch Pressure (21.112).
Check the regulated clutch pressure. The pressures are within specifica- The pressure is out of range. In-
Refer to Power Shuttle transmis- tions. Go to Power Shuttle trans- spect the input shaft sealing rings
sion - Test — Checking Regulated mission - Testing — Machine Will and clutch piston seals. Inspect the
Clutch Pressure (21.112) Not Move (21.112) forward and reverse clutch friction
discs. Repair or replace as required.
Power Shuttle transmission - Testing - Transmission Oil is Too Hot

Check the transmission oil cooler for The transmission oil cooler is clean. The transmission oil cooler is dirty
air flow restrictions. Clean the exte- Go to next step. and there are air flow restrictions.
rior of the transmission oil cooler as Clean the exterior of the transmis-
required. sion oil cooler as required. Go to the
next step if the problem still exists.
Check the converter IN pressure. The converter IN pressure is within The converter pressure is not within
Refer to Power Shuttle transmis- specifications. Go to next step. specifications. Refer to Power
sion - Test — Checking Converter Shuttle transmission - Testing —
In Pressure (21.112) Machine Will Not Move (21.112)
Check the converter OUT pressure. The converter OUT pressure is The converter OUT pressure is
Refer to Power Shuttle transmis- within specifications. Go to next not within specifications. Refer
sion - Test — Checking Converter step. to Power Shuttle transmission -
Out Pressure (21.112). Testing — Machine Will Not Move
(21.112)
Check the lube pressure. Refer to The lube pressure is within specifica-
Power Shuttle transmission - Test tions. STOP. The pressure is not within
Checking Lubrication Pressure specifications. If the torque
(21.112). converter pressure is high and
the lube pressure is low, possible
causes include:
• Restriction in the oil cooler.
Replace the oil cooler. The
transmission oil cooler cannot
be flushed or cleaned out. The
complete oil cooler must be re-
placed is a restriction is found.
• The oil cooler circuit is re-
stricted. Inspect the oil cooler
circuit and repair as required.
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Power Shuttle transmission - Testing Problem in the Parking Brake

System
Does the parking brake release? The parking brake will release. Refer
to Parking brake disks - Inspect Check the electrical and hydraulic
(33.110) and Parking brake disks - circuits.
Test (33.110). If the parking brake • Check the differential lock
will not hold the machine, repair or pressure, refer to Power Shut-
replace the disc brakes. tle transmission - Test —
Checking Differential Lock
Valve (21.112). The differen-
tial lock and the parking brake
are on the same pressure cir-
cuit. If the differential lock
pressure is within specifica-
tions, refer to Power Shut-
tle transmission - Pressure
test – 2 Wheel Drive, Test
One — Engine at Idle 900 to
1100 rpm (21.112) and Power
Shuttle transmission - Pres-
sure test — 2 Wheel Drive,
Test Two — Engine at 2200
rpm (21.112) OR Power Shut-
tle transmission - Pressure
test – 4 Wheel Drive, Test
One — Engine at Idle 900 to
1100 rpm (21.112) and Power
Shuttle transmission - Pres-
sure test — 4 Wheel Drive,
Test Two — Engine at 2200
rpm (21.112).
• Check fuses, replace fuses as
required.
• Check switch operation, repair
or replace as required.
• Measure the solenoid resis-
tance. The resistance should
be approximately 9.8 Ω at 20
°C (68 °F). Replace the sole-
noid as required.
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Index
Transmission - 21

Power Shuttle transmission - Check Checking Supply Pump Pressure (4WD Only) . . . . . . . . . . . . . . . . . . . . . . . . 35
Power Shuttle transmission - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power Shuttle transmission - Exploded view - Four wheel drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Power Shuttle transmission - Exploded view - Two wheel drive transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power Shuttle transmission - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power Shuttle transmission - Hydraulic schema - Four Wheel Drive Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Power Shuttle transmission - Hydraulic schema - Two Wheel Drive Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Shuttle transmission - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Power Shuttle transmission - Pressure test - 4 Wheel Drive, Test Two - Engine at 2200 rpm . . . . . . . . . . . . . . . . . 49
Power Shuttle transmission - Pressure test – 2 Wheel Drive, Test One - Engine at Idle 900 to 1100 rpm . . . . . . 42
Power Shuttle transmission - Pressure test – 4 Wheel Drive, Test One - Engine at Idle 900 to 1100 rpm . . . . . . 48
Power Shuttle transmission - Pressure test - 2 Wheel Drive, Test Two - Engine at 2200 rpm . . . . . . . . . . . . . . . . . 43
Power Shuttle transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Power Shuttle transmission - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power Shuttle transmission - Test - Checking Converter In Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Power Shuttle transmission - Test - Checking Converter Out Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Power Shuttle transmission - Test - Checking Differential Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Power Shuttle transmission - Test - Checking Regulated Clutch Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Shuttle transmission - Test Checking Lubrication Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Power Shuttle transmission - Test Checking Supply Pump Flow and Relief Pressure . . . . . . . . . . . . . . . . . . . . . . . 38
Power Shuttle transmission - Testing - Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Power Shuttle transmission - Testing - Machine Hesitates When Shifting Between Forward and Reverse . . . . 100
Power Shuttle transmission - Testing - Machine Will Not Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Power Shuttle transmission - Testing - Transmission Oil is Too Hot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Power Shuttle transmission - Testing - Will Not Go Into 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Power Shuttle transmission - Testing Problem in the Parking Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Power Shuttle transmission - Tool connection - Pressure Test Ports, Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . 45
Power Shuttle transmission - Tool connection Pressure Test Ports 4 Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Power Shuttle transmission - Tool connection Four Wheel Drive Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . 47
Power Shuttle transmission - Tool connection Two Wheel Drive Port Identification . . . . . . . . . . . . . . . . . . . . . . . . . 44
Power Shuttle transmission - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission housing - Assemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Transmission housing - Assemble - Transmission housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Transmission housing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
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Transmission housing - Disassemble - Shift rods and shift forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Transmission housing - Disassemble - Shifter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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Transmission - 21
Powershift transmission - 113
580N
580SN WT
580SN
590SN
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Contents
Transmission - 21
TECHNICAL DATA
Powershift transmission
General specification - H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General specification - S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Torque - S-type (SPS Power Synchro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
General specification - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Special tools - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Torque - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
General specification Trax Controller Pin Out Guide, S-Type Transmission . . . . . . . . . . . . . . . . . . . . . . . . 26
FUNCTIONAL DATA
Exploded view - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Exploded view - H-type - 1st, 3rd, 4th gear shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Exploded view - H-type - transmission assembly - 4 wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Exploded view - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Exploded view - S-type (SPS Power Synchro) - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Exploded view - S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Exploded view - S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Exploded view - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Exploded view - S-Type (SPS Power Synchro) - Rear cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Exploded view - S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Exploded view - S-type (SPS power synchro) - Shaft A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Exploded view - S-Type (SPS Power Synchro) - Shafts B - C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Exploded view -S-type (SPS power synchro) - transmission assembly - 4 wheel drive shaft . . . . . . . . . 52
Exploded view - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Overview S-Type Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Hydraulic schema H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Hydraulic schema S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
SERVICE
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Disassemble - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Assemble - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Disassemble - S-type (SPS power synchro)- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Assemble - S-type (SPS power synchro) Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Remove - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Install - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Disassemble - H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Cleaning - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Inspect - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Assemble - H-type - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
View Troubleshooting and Monitoring EST Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Tool connection Test Port and Component Locations, H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Tool connection Test Port and Component Locations, S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Warm up Heating the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Transmission housing
Disassemble - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Assemble - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
DIAGNOSTIC
Testing Machine Will Not Move, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Testing Loss of Power, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Testing Wheels Rotate When Vehicle is Raised, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Testing Transmission Oil is Too Hot, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Testing Noisy Transmission, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Testing Irregular Clutch Activation, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Testing Gear Remains Engaged, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Testing Will Not Go Into 4WD, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Testing Problem in the Parking Brake System, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
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Transmission - Powershift transmission
Powershift transmission - General specification - H-type

Type Carraro TLB1 2WD & 4WD SPS - SAHR Parking Brake
Lubricant - Carraro TLB1 2WD& 4WD SPS - SAHR Parking Brake

Total system capacity 19.5 l (20.6 US qt)
Refill capacity with or without filter change 16 l (16.9 US qt)
Type of fluid Case AKCELA Hy-Tran™ Ultra (CASE MS1209) (CNH
MAT 3505)
Specifications
NOTE: All pressures and flows must be measured with an oil temperature of 80 °C (176 °F).
Parameter Operating Pressure / Temperature

Forward and reverse clutch pressures at 2200 RPM 13.5 - 16.5 bar (196 - 239 psi), clutch activated
0 - 0.3 bar (0 - 4.4 psi), clutch released
Filter bypass valve 8 - 11 bar (116 - 160 psi)
Lube pressure 1 - 5 bar (15 - 73 psi)
Torque converter inlet pressure 3 - 9 bar (43.5 - 130.5 psi)
Differential lock 14 - 17 bar (203 - 246.5 psi)
Brake booster port 14 - 17 bar (203 - 246.5 psi)
Park brake pressure switch 9 - 11 bar (130.5 - 159.5 psi)
Park brake check port 13.5 - 15.5 bar (195.8 - 224.8 psi)
Vehicle may move during the park brake pressure check,
monitor park brake pressure from inside of cab by
removing the floor plate.
Pump flow at 900 RPM bench test before filter 19 l/min (5 US gpm)
1st gear at 900 RPM 11.5 - 14.5 bar (166.8 - 210.3 psi)
1st gear at 2200 RPM 13 - 15.5 bar (188.5 - 224.8 psi)
2nd gear at 900 RPM 14 - 16.5 bar (203.0 - 239.3 psi)
2nd gear at 2200 RPM 15.5 - 18 bar (224.8 - 261.0 psi)
3rd gear at 900 RPM 14 - 16.5 bar (203.0 - 239.3 psi)
3rd gear at 2200 RPM 15.5 - 18 bar (224.8 - 261.0 psi)
4th gear at 900 RPM 14 - 16.5 bar (203.0 - 239.3 psi)
4th gear at 2200 RPM 15.5 - 18 bar (224.8 - 261.0 psi)
4WD check port at 900 RPM 13.5 - 15 bar (195.8 - 217.5 psi)
4WD check port at 2200 RPM 14.5 - 16.5 bar (210.3 - 239.3 psi)
Forward/ Reverse clutch solenoids 7.15 Ω at 20 °C (68 °F)
4WD solenoid 7.15 Ω at 20 °C (68 °F)
Park brake solenoid 9.8 Ω at 20 °C (68 °F)
S 1/3 solenoid 7.15 Ω at 20 °C (68 °F)
S 2/4 solenoid 7.15 Ω at 20 °C (68 °F)
PWM 1/3 solenoid 7.25 Ω at 20 °C (68 °F)
PWM 2/4 solenoid 7.25 Ω at 20 °C (68 °F)
Powershift transmission - General specification - S-Type

NOTE: All transmission pressures are to measured with an oil temperature of 80 °C (176 °F)
Item Pressure Minimum/Maximum

Control valve supply pressure 13 bar (189 psi) @ 900 RPM
17 bar (247 psi) @ 2400 RPM
Forward or reverse clutch pressure 12 bar (174 psi) @ 900 RPM
16 bar (232 psi) @ 2400 RPM
1N2, 3N4, 1st, 2nd, 3rd, 4th, HDL, 4WD 13 bar (189 psi) @ 900 RPM
17 bar (247 psi) @ 2400 RPM
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Item Pressure Minimum/Maximum

Torque converter inlet 1.5 bar (22 psi) @ 900 RPM
10 bar (145 psi) @ 900 RPM
Brake booster port 13 bar (189 psi) @ 900 RPM
17 bar (247 psi) @ 2400 RPM
Powershift transmission - Special tools

RCPH11TLB020BAL 1
RCPH11TLB022BAL 2
CAS-10280 Flowmeter
RCPH11TLB024BAL 3
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Powershift transmission - Torque - S-type (SPS Power Synchro)

(1) 28 N·m (20.7 lb ft)
(2) 23 N·m (17.0 lb ft)
(3) 40 N·m (29.5 lb ft)
(4) 50 N·m (36.9 lb ft)
(5) 139 N·m (102.5 lb ft)
(6) 50 N·m (36.9 lb ft)
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RCPH10TLB145GAL 1
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(1) 50 N·m (36.9 lb ft)

(2) 23 N·m (17.0 lb ft)
(3) 100 N·m (73.8 lb ft)
(4) 50 N·m (36.9 lb ft)
(5) 25 N·m (18.4 lb ft)
(6) 25 N·m (18.4 lb ft)
(7) 4.8 - 6.8 N·m (3.5 - 5.0 lb ft)
(8) 26 - 29 N·m (19.2 - 21.4 lb ft)
(9) 60 N·m (44.3 lb ft)
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RCPH10TLB146GAL 2
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(1) 30 N·m (22.1 lb ft)

(2) 26 - 30 N·m (19.2 - 22.1 lb ft)
(3) 23 N·m (17.0 lb ft)
(4) 25 N·m (18.4 lb ft)
(5) 30 N·m (22.1 lb ft)
(6) 23 N·m (17.0 lb ft)
(7) 30 N·m (22.1 lb ft)
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RCPH10TLB147GAL 3
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(1) 3 - 4 N·m (2.2 - 3.0 lb ft)

(2) 25 N·m (18.4 lb ft)
(3) 50 N·m (36.9 lb ft)
(4) 50 N·m (36.9 lb ft)
(5) 23 N·m (17.0 lb ft)
(6) 26 - 29 N·m (19.2 - 21.4 lb ft)
(7) 10 N·m (7.4 lb ft)
(8) 4.8 - 6.8 N·m (3.5 - 5.0 lb ft)
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RCPH10TLB148GAL 4
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(1) 139 N·m (102.5 lb ft)

(2) 23 N·m (17.0 lb ft)
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RCPH10TLB149GAL 5
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(1) 40 N·m (29.5 lb ft)

(2) 50 N·m (36.9 lb ft)
(3) 50 N·m (36.9 lb ft)
(4) 50 N·m (36.9 lb ft)
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RCPH10TLB150GAL 6
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(1) 30 N·m (22.1 lb ft)

(2) 30 N·m (22.1 lb ft)
(3) 30 N·m (22.1 lb ft)
(4) 40 N·m (29.5 lb ft)
(5) 30 N·m (22.1 lb ft)
(6) 30 N·m (22.1 lb ft)
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RCPH10TLB151GAL 7
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Powershift transmission - General specification - H-type - 4WD only

Type Carraro TLB2 PB CD 4WD 2WS
Lubricant
Total system capacity 17.9 l (18.9 US qt)
Refill capacity with or without filter change 11.3 l (11.9 US qt)
Type of fluid Case AKCELA Hy-Tran™ Ultra
Powershift transmission - Special tools - H-type - 4WD only

380040161 - Teflon seal installation kit
RCPH10TLB828AAL 1
380002211 - Handle
RCPH10TLB059AAL 2
380040161 - Teflon seal ring protector and shims - 1st,

3rd, 4th, and 4WD shafts
RCPH10TLB080AAL 3
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380100081 - Teflon seal ring protector and shims - 2nd

gear
RCPH10TLB073AAL 4
380100082 - Teflon seal ring sizer - 2nd gear
RCPH10TLB074AAL 5
380100083 - Teflon seal ring protector - 1st gea r
RCPH10TLB072AAL 6
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380100084 - Teflon seal ring sizer - 1st gear
RCPH10TLB078AAL 7
380100085 - Teflon seal ring protector and shim - 1st gear

bushing
RCPH10TLB079AAL 8
380100086 - Teflon seal ring sizer - 1st gear bushing
RCPH10TLB075AAL 9
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380100087 - Holder bushing - 4WD shaft
RCPH10TLB076AAL 10
380100088 - Shaft puller/installer
RCPH10TLB077AAL 11
CAS2379 - Holder and spring compressor
RCPH10TLB043ABL 12
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Powershift transmission - Torque - H-type - 4WD only
RCPH10TLB14GAL 1
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RCPH10TLB15GAL 2
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Powershift transmission - General specification Trax Controller Pin

Out Guide, S-Type Transmission
RCPH11TLB014FAL 1
Connector view from end of connector.
Pin Wire # Function Check Notes

1 2P01 Red TRAX B+ 12 volts at all times From fuse F-024
2 5207 Yellow In Gear input 12 volts in FWD or REV From forward and
reverse diodes
3 3053 White FWD Coil positive 12V PWM forward
4 3063 White REV Coil positive 12V PWM reverse
5 19ED Orange TRAX Key ON 12V when key is on From fuse F-009
6 3043 White S2 Solenoid pos 12V for 2nd gear
7 3593 White S3 Solenoid pos 12V for 3rd gear
8 19EC Orange TRAX Key ON 12V when key is on From fuse F-009
9 3013 White S1 Solenoid pos 12V for 1st gear
10 N/C
11 3573 White HDL Coil pos 12V when HDL is on
12 3073 Gray FWD Coil neg 12V PWM forward
13 N/C
14 N/C
15 3151 Pink 5V sensor + 5V to resistor network
16 21C7 Yellow Neutral Input 12V when in neutral From FNR Lever
17 0401 Blue Sensor ground Ground at all times For sensor and resistor
network
18 25A5 Light Forward input 12V when in forward From FNR lever
Blue
19 1902 Yellow Gear Command 1 12V in 1st and 4th From FNR lever
20 N/C
21 4062 Yellow Declutch input 12V when declutch From declutch switch
or SAHR relay
22 25C2 Yellow 4WD input 12V when 4WD From 4WD switch
23 N/C
24 N/C
25 3301 Blue Speed sensor Frequency 0–15 kHz Check using EST
26 N/C
27 E356 Yellow CAN High >2.5 VDC Connects to CAN bus
backbone
28 N/C
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Pin Wire # Function Check Notes

29 G101 Black TRAX Ground Ground at all times Chassis ground at
loader handle stud
30 N/C
31 N/C
32 N/C
33 N/C
34 19EB Orange TRAX key on 12V when key is on From fuse F-009
35 N/C
36 N/C
37 N/C
38 3023 White S4 Solenoid pos 12V for 4th gear
39 25X3 White 4WD coil pos 12V in 2nd Solenoid energized in
2WD
40 3083 Gray Rev coil neg 12V PWM reverse
41 N/C
42 N/C
43 3431 Yellow Temp sensor 10k ohms @ 25 °C (77 °F) Check using EST
44 3441 Yellow Pressure sensor Ground > 9.5 bar (138 psi) Check using EST
45 3451 Yellow 3rd/4th analog V 1, 2, 3 or 4 volts Depending on gear
position switches
46 25B6 Light Reverse Input 12V in reverse Fron FNR lever
Blue
47 3223 Yellow Gear command 2 12V in 3rd and 4th From FNR lever
48 N/C
49 3214 Yellow Kickdown input 12V to kickdown to 1st Active only when in
2nd gear
50 N/C
51 25S1 Yellow HDL input 12V when diff lock From HDL button on
loader handle
52 N/C
53 31S2 Yellow Tach Frequency from alternator Back up RPM signal
54 3541 Yellow 1st/2nd Analog V 1, 2, 3 or 4 volts Depending on gear
position switches
55 E346 Green CAN Low < 12VDC Connects to CAN bus
backbone
56 N/C
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Powershift transmission - Exploded view - Powershift H-type

1. Nut (2) 90-100 NM (67-73 lb-ft) 8. Flex plate
2. Transmission 9. Backing plate
3. Bolt (12) 52-57 NM (38-42 lb-ft) 10. Cap screw (4) 52-57 NM (38 - 42 lb-ft)
4. Dipstick tube 11. Bolt (4) 52-57 NM (38 - 42 lb-ft)
5. Bolt (2) 27-31 NM (20-23 lb-ft) 12. Nut 90-100 NM (67-73 lb-ft)
6. Converter 13. Rubber transmission mount (2)
7. Flex plate with caged nut 14. Constant torque clamp (4) 5.6 - 7.9 NM (50-70 in-lb)
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RCPH10TLB6GAL 1
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Powershift transmission - Exploded view - H-type - 1st, 3rd, 4th

gear shaft
1st, 3rd, 4th gear shaft
1. Bearing 15. Teflon seal ring 29. 4th gear clutch 43. O-ring
2. Thrust washer 16. Seal rings 30. Thrust plate 44. Bushing
3. Gear 17. Plug 31. Lock ring 45. O-ring
4. Lock ring 18. Spring pin 32. Gear 46. Roller bearing
5. Thrust plate 19. Spring pin 33. Roller retainer 47. Bushing
6. 3rd gear clutch 20. Gear 34. Gear 48. Teflon seal ring
7. Roller retainer 21. Teflon seal ring 35. Lock ring 49. Teflon seal ring
8. Thrust washer 22. Teflon seal ring 36. Thrust plate 50. Teflon seal ring
9. Snap ring 23. Clutch piston 37. 1st gear clutch 51. Gear
10. Retaining plate 24. Bushing 38. Lock ring 52. Roller bearing
11. Spring 25. Spring 39. Retaining plate 53. Bushing
12. Bushing 26. Retaining plate 40. Spring 54. Thrust bearing
13. Clutch piston 27. Lock ring 41. Clutch piston 55. Bearing
14. Teflon seal ring 28. Thrust washer 42. Teflon seal ring
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RCPH10TLB17GAL 1
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Powershift transmission - Exploded view - H-type - transmission

assembly - 4 wheel drive shaft
Transmission Assembly
1. Bearing 13. Plug
2. Ring 14. Counter disk
3. Shim 15. Clutch pack
4. Washer 16. Thrust plate
5. Bellville washers 17. Lock ring
6. Bushing 18. Gear
7. O-ring 19. Needle bearing
8. Clutch piston 20. Spacer
9. O-ring 21. Bearing
10. Pin 22. Seal ring
11. O-ring 23. Seal ring
12. Clutch housing
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RCPH10TLB16GAL 1
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Powershift transmission - Exploded view - S-Type (SPS Power

Synchro) - Filters
Filters
1. Drain plug 6. Spin-on filter
2. Cap screws 7. Connector
3. Cover 8. Cap screws
4. O-ring 9. Support
5. Oil filter 10. O-ring
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RCPH10TLB152GAL 1
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Powershift transmission - Exploded view - S-type (SPS Power

Synchro) - Oil pump
Oil pump
1. Seal ring 3. Oil pump
2. Screws 4. O-ring
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RCPH10TLB153GAL 1
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Synchro) - Switches and sensors
Switches and sensors
1. Screws 9. Washer seal
2. Gaskets 10. Speed sensor
3. Pipe 11. Screw
4. Temperature sensor and thermostat 12. Bracket
5. Wiring harness 13. Switch gear
6. Regulating pressure valve 14. O-ring
7. Washer 15. Spring
8. Pressure switch 16. Switch detents
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RCPH10TLB154GAL 1
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Synchro) - Hydraulic control valve
Hydraulic control valve
1.Screw 7. Valve
2. Gasket 8. Valve
3 Control valve 9. Valve
4. Screws 10,11,12. O-ring
5. Screws 13. Screws
6. Valve
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RCPH10TLB155GAL 1
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Synchro) - Front housing
Front housing
1. O-ring 12. Gears
2. Retaining screw 13. Gears
3. Washer 14. Nut
4. O-ring 15. Oil pump
5. Flange 16. Screws
6. Cap screws 17. Housing
7. Cover 18. Primary shaft
8. O-ring 19. Secondary shaft
9. Seal 20. Front housing
10. Bearing 21. Drain plug
11. O-rings 22. Four-wheel drive clutch tube
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RCPH10TLB156GAL 1
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Synchro) - Rear cover
Rear cover
1. O-ring 11. Shims
2. Screws 12. Bearing snap ring
3. Flange 13. Screws
4. Rear cover 14. Drain plug
5. Teflon seal ring 15. Pin
6. PTO shaft 16.Rear front housing
7. Bearing 17. Housing
8. Snap ring 18. Screws
9. Screws 19. Parking brake
10. Screws 20. O-ring
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RCPH10TLB157GAL 1
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Synchro) - Gear pistons
Gear pistons
1. Screws 13. Screws
2. Plate 14. O-ring
3. Plugs 15. Drain plug
4. O-ring 16. Neutral piston
5. Plugs 17. O-ring
6. O-ring 18. 3rd gear piston
7. Shims 19. Seal ring
8. Screws 20. 1st gear piston
9. Neutral piston 21. O-ring
10. O-ring 22. 2nd gear piston
11. Screw 23. 4th gear piston
12. Oil circuit plate
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RCPH10TLB158GAL 1
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Powershift transmission - Exploded view - S-type (SPS power

synchro) - Shaft A - D
Shafts A - D
1. Seal ring 11. Clutch plate lock ring 21. Teflon seal ring 31. Split pin
2. Snap ring 12. Needle cage 22. Teflon seal ring 32. Spring cover
3. Bearing 13. Spring cover 23. Snap ring 33. Snap ring
4. Spacer 14. Snap ring 24. Bearing 34. Spring
5. Sleeve 15. Spring 25. Thrust washer 35. Clutch drive plate
6. Gear 16. Shaft bearing 26. Gear 36. Clutch plate
7. Needle cage 17. Clutch drive plate 27. Sleeve 37. Shaft bearing
8. Thrust washer 18. Clutch plate 28. Thrust washer 38. Clutch piston
9. Split pin 19. Clutch piston 29. Lock ring 39. Teflon seal ring
10. Lock ring 20. Teflon seal ring 30. Teflon seal ring 40. Snap ring
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RCPH10TLB002GAN 1
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Synchro) - Shafts B - C
Shafts B - C
1. Bearing 12. Fourth speed gear 23. First/second speed 34. Springs
synchronizer assembly
2. Thrust washer 13. Snap ring 24. Steel ring 35. Hub
3. Third speed gear 14.4WD gear 25. Tapered friction ring 36.
4. Speed synchronizer 15. Outer race bearing 26. Sintered ring 37. First speed gear
assembly
5. Clutch ring 16. Snap ring 27. Synchronizer ring 38. Snap ring
6. Tapered friction ring 17. Thrust washer 28. Tapered friction ring 39. Inner race bearing
7. Sleeve 18. Second speed gear 29. Steel ring 40. Bearing
8. Plates 19. Split pin 30. Sintered ring 41. Shaft
9. Balls 20. Shims 31. Sleeve
10. Hub springs 21. Shaft 32. Balls
11. Synchronizer hub 22. Synchronizer ring 33. Plates
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RCPH10TLB160GAL 1
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Powershift transmission - Exploded view -S-type (SPS power

synchro) - transmission assembly - 4 wheel drive shaft
Shaft E - 4WD
1. Snap ring 7. Four wheel drive clutch tube
2. Washer 8. Teflon sealing rings
3. Spacer 9. O-ring
4. Springs 10. Four wheel drive clutch gear
5. Sleeve 11. Bearing
6. O-ring
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RCPH10TLB161GAL 1
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Synchro) - Shift rails - forks
Shift rails - forks
1. Shift forks - 1st and 2nd gear 3. Shift rail
2. Shift forks - 3rd and 4th gear 4. Spring pins
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RCPH10TLB162GAL 1
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Powershift transmission - Overview S-Type Transmission

The Powershift S-type transmission is an optional transmission introduced for the Case N series loader backhoes.
It is offered in 2WD and 4WD configurations, and incorporates a spring applied hydraulic release (SAHR) parking
brake at the rear transmission output shaft. Torque from the engine is transferred into the gearbox by a conventional
hydraulic torque converter. Gear reduction is achieved by constant-mesh spur gear type of gear train. Mechanically,
the Powershift S-type transmission is very similar to the Power shuttle transmission which has been used in the Case
loader backhoes for many years. This transmission offers 4 forward and 3 reverse speeds, and all speed range
gears are shifted by dog type synchronizers with blocking rings. The synchronizers are shifted by two shift forks, one
for the 1st and 2nd gears, and the other for the 3rd and 4th gears. The forks are mounted to shift rails which are
positioned by hydraulic pressure. Forward and Reverse are hydraulically engaged by multi-plate clutch packs. The
transmission oil to engage the clutches, shift, lubricate bearings, provide fluid for the torque converter, and cool the
transmission is supplied by a charge pump driven by tangs on the torque converter. The fluid to move the shift rails
and clutches is controlled by electric solenoids at a control valve manifold mounted to the top of the transmission. The
electric solenoids are actuated by an electronic transmission controller (TRAX). There is no automatic shifting mode
with this transmission, and the transmission will shift gears only as requested by input from the operator. A hydraulic
pump drive shaft engages splines in the front of the torque converter housing and carries torque through the center
of the hollow input shaft, engaging the machine hydraulic pump at a mounting flange at the rear. The Powershift
S-type transmission uses the same Case Hytran Ultra fluid as used in the hydraulic system, as well as the other two
transmission options for the N series loader backhoes.
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Powershift transmission - Hydraulic schema H-Type
RCPH11TLB003HAL 1
(1) SAHR parking brake (16) Oil flow divider/ pressure regulator valve
(2) 4WD SAHR clutch (17) Spin-on filter
(3) 3rd gear clutch (18) Oil filter relief valve
(4) 4th gear clutch (19) Transmission oil pump
(5) Forward clutch (20) Torque converter
(6) Reverse clutch (21) Oil cooler
(7) Forward clutch pressure check port (22) Temperature thermostat
(8) Reverse clutch pressure check port (23) Air breather
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(9) 1st gear clutch (24) Suction filter

(10) 2nd gear clutch (25) Torque converter pressure relief valve
(11) 1st gear clutch pressure check port (26) Brake oil port return to sump
(12) 2nd gear clutch pressure check port (27) Output shafts lubrication
(13) Differential lock port (28) Primary shaft lubrication
(14) Parking brake solenoid valve (29) Input shaft lubrication
(15) Auxiliary ports
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Powershift transmission - Hydraulic schema S-Type

(1) SAHR parking brake (17) Forward
(2) SAHR park brake valve (18) S4
(3) TC relief (19) S2
(4) Breather (20) S3
(5) Cold oil by-pass (21) S1
(6) Oil filter and by-pass (22) Pressure sensor
(7) Screen (23) 1N2
(8) Pump (24) 3N4
(9) Pressure regulator (25) Forward clutch
(10) TC (26) Reverse clutch
(11) Oil cooler (27) SAHR 4WD
(12) Temperature sensor (28) 2nd gear
(13) Transmission control valve unit (29) 1st gear
(14) HDL (30) 4th gear
(15) 4WD (31) 3rd gear
(16) Reverse (32) Bearing
(33) Hose
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RCPH11TLB018GAL 1
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Powershift transmission - Disassemble - S-Type (SPS Power

Synchro) - Filters
transmission
RCPH10TLB081AAL 1
2. Remove the two cap screws (1)which fasten the

cover for the oil screen. Remove the cover (2).
RCPH10TLB082AAL 2
3. Remove the oil filter (1)and the O-ring (2). Handle

and washer the filter according to authorized proce-
dures. In case of replacement, use only authorized
disposal procedures.
RCPH10TLB083AAL 3
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4. Remove the filter
RCPH10TLB249AAL 4
5. If necessary remove the connector for the filter.
RCPH10TLB092AAL 5
Next operation:
Powershift transmission - Assemble (21.113)
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Powershift transmission - Assemble - S-Type (SPS Power Synchro)

- Filters
Prior operation:
Powershift transmission - Disassemble (21.113)
1. Assemble the O-Ring (1). Assemble the support (2).

Assemble the two screws (3)which fasten the sup-
port of the spin-on filter. Torque to Powershift trans-
mission - Torque (21.113) Powershift transmis-
sion - Torque (21.113)
RCPH10TLB035ACL 1
2. Assemble the connector (1)of the spin-on filter (2).

Torque wrench Powershift transmission - Torque
(21.113).
RCPH10TLB034ACL 2
NOTE: Put a thin coat of oil transmission on the filter gasket, turn clockwise until the gasket makes contact with the
base, continue to turn the filter 2/3 turn.
3. Assemble filter and O-ring after having washed or
replaced it.
RCPH10TLB250AAL 3
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4. Assemble cover and screws Tightening torque 50

N·m (36.9 lb ft).
RCPH10TLB082AAL 4
5. Assemble plug (1). Tightening torque 139 N·m

(102.5 lb ft).
RCPH10TLB081AAL 5
Next operation:
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Powershift transmission - Disassemble - S-type (SPS power

synchro)- Oil pump
1. Remove the screws.
RCPH10TLB094AAL 1
2. Remove the pump using the two levers.
RCPH10TLB251AAL 2
3. Remove the oil pump.
RCPH10TLB252AAL 3
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4. If replacement is necessary, remove the O-ring.
RCPH10TLB095AAL 4
5. Remove the seal ring, if replacement is necessary.
RCPH10TLB096AAL 5
Next operation:
Powershift transmission - Assemble (21.113)
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Powershift transmission - Assemble - S-type (SPS power synchro)

Oil pump
Prior operation:
1. Use a soft faced hammer and a suitable tool to as-

semble new seal ring (1) on oil pump (2).
RCPH10TLB014ACL 1
2. Install O-ring.
RCPH10TLB095AAL 2
3. Prior to oil pump assembly, ensure marks line up

between oil pump and half-case.
RCPH10TLB098AAL 3
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4. Grease the ring to keep it centered to the shaft slot

center line to help fit the pump.
RCPH10TLB099AAL 4
5. Apply a thin film of transmission oil on the coupling

seat with the front half-case. Assemble the oil pump.
RCPH10TLB099AAL 5
6. Install screws (1) and torque to Powershift trans-

mission - Torque (21.113)
NOTE: Ensure the marks on the oil pump and bellhouse line up.
Next operation:
Transmission electronic control module Powershift - Disassemble (55.024)
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Powershift transmission - Remove - Powershift H-type

1. Park the machine on a level surface. Put the back-
hoe in the transport position with the stabilizers
down. Also put the loader bucket on the floor.
2. Raise the wheels off the floor high enough to re-
move the transmission. Put suitable stands under
both sides of the machine at the front and rear.
NOTE: The rear wheels can be removed to ease the transmission removal.
3. Loosen and remove the cap screw and washer (1)
for the left rear mounting bracket on front drive shaft
guard through the access hole in the fuel tank.
RCPH10TLB060AAL 1
4. Loosen and remove the bolts, washers, and nuts (2)

that fasten the left rear mounting bracket to the front
drive shaft guard. Remove the left rear mounting
bracket.
RCPH10TLB062AAL 2
5. Put a floor jack under the drive shaft guard that will
hold the guard in place when the cap screws are
removed. Loosen and remove the cap screws and
washers (3)from the remaining mounting brackets on
the front drive shaft guard. Remove the front drive
shaft guard from the machine.
RCPH10TLB061AAL 3
NOTE: Powershift transmission have spacers and O-rings on the bolts, they are required for assembly.
6. Remove the retainer and bolts that fasten the front
drive shaft to the transmission output shaft yoke. Re-
move the front drive shaft from the splined pinion
shaft on the front axle.
NOTE: During installation apply Loctite 243 to the bolts for the retainer. Tighten the bolts to 33 to 39 Nm (24 to 29
pound-feet).
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7. Remove the retainer and bolts that fasten the rear

drive shaft to the transmission output shaft yoke. Re-
move the rear drive shaft from the splined pinion
shaft on the rear axle.
RCPH10TLB069AAL 4
NOTE: During installation apply Loctite 243 to the bolts for the retainer. Tighten the bolts to 33 to 39 Nm (24 to 29
pound-feet).
8. Put a container under the drain plug that will hold
approximately 22 liters (6 U.S. gallons). Remove the
fill plug and the drain plug.
RCPH10TLB070AAL 5
9. Remove hydraulic pump from the transmission.

10. Tag and disconnect the transmission cooler inlet and
outlet hoses at the transmission. Install caps on the
transmission fittings and plugs in the hose ends.
11. Disconnect the electrical connector for the transmis-
sion control valve harness, remove the mounting bolt
for the connector mounting bracket.
RCPH10TLB067AAL 6
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12. Disconnect the supply line (1) from the transmission,

disconnect the return line (2) from the transmission.
RCPH10TLB167ABL 7
13. Disconnect the electrical connector for the SAHR

parking brake.
14. Disconnect the hose for the differential lock.
15. Remove the starter from the engine. Remove the
access cover from the bell housing.
RCPH10TLB026AAL 8
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16. Install the engine turning tool, 380000988, to turn the

flywheel for access to the cap screws.
RCPH10TLB005BAL 9
17. Loosen and remove the four cap screws that fasten
the flywheel to the flex plate.
RCPH10TLB027AAL 10
NOTE: During installation make sure that the converter is in the correct position on the transmission shaft. Align the
hole sin the flex plate with the holes in the flywheel. Install but do not tighten all four cap screws, then final torque the
cap screws to 52 to 57 Nm (38 to 42 pound-feet).
18. Use acceptable stands or blocks to secure the en-
gine in place.
19. Install a transmission jack under the transmission
and apply light pressure.
20. Loosen and remove the 12 cap screws and flat wash-
ers that fasten the transmission to the engine.
21. Remove both the left and right transmission mount-
ing cap screw.
NOTE: During installation tighten the transmission mounting cap screws to a torque of 90 to 100 Nm (67 to 73 pound-
feet), install two nuts on the left mount.
22. Carefully slide the transmission away from the en-
gine. Lower to the ground and remove from under
the machine.
Next operation:
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Powershift transmission - Install (21.113)
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Powershift transmission - Install - Powershift H-type

NOTE: Install the transmission in reverse of removal.
1. Mount the transmission to the engine, torque the
mounting bolts to 52 to 57 Nm (38 to 42 pound-feet).
NOTE: Rotate the torque converter through the bottom hole of the bell housing and slide it against the adapter plate.
Align the bolt hole with the bosses on the torque converter.
2. Install and hand tighten all four cap screws that fas-
ten the flywheel to the torque converter.
3. Final torque the cap screws to 52 to 57 NM (38 to 42
pound-feet).
4. Remove the engine turning tool.
5. Install the access cover on the bell housing. Install
the starter on the engine.
RCPH10TLB026AAL 1
NOTICE: Before starting the engine, do the following.

6. Make sure the transmission drain plug has been in-
stalled and tightened.
7. Fill the transmission.
NOTE: If removed, install the rear wheels.

8. Remove the stands from under the machine and
lower the machine to the ground.
9. With the machine parked on level ground and the
engine running at low idle, check the transmission
oil level. The oil level must be between the ADD and
the FULL marks on the dipstick. If the oil level is at
the ADD mark, add oil as required until the oil level
is at the FULL mark.
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Powershift transmission - Disassemble - H-type

1. Clean exterior of the transmission and place on a
suitable stand.
transmission.
RCPH10TLB081AAL 1
3. Remove the two cap screws which fasten the cover

for the oil suction filter.
RCPH10TLB082AAL 2
4. Remove the cover, filter, and O-ring.
RCPH10TLB083AAL 3
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5. Remove the filter.
RCPH10TLB249AAL 4
6. If necessary remove the connector for the filter.
RCPH10TLB092AAL 5
7. Loosen the oil filter bypass valve.
RCPH10TLB084AAL 6
8. Remove the filter bypass valve.
RCPH10TLB085AAL 7
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9. Remove the breather from the transmission only if

the breather is damaged or leaking.
RCPH10TLB086AAL 8
10. Remove forward clutch test port plug if O-ring is leak-

ing, replace O-ring and torque to 30 Nm (22 pound
feet).
RCPH10TLB087AAL 9
11. Remove reverse clutch test port plug if O-ring is leak-

ing, replace O-ring and torque to 30 Nm (22 pound
feet).
RCPH10TLB088AAL 10
12. Remove lubrication pressure test port plug if O-ring

is leaking, replace O-ring and torque to 30 Nm (22
pound feet).
RCPH10TLB089AAL 11
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13. Remove the speed sensor.
RCPH10TLB090AAL 12
14. Remove the thermostat.
RCPH10TLB091AAL 13
15. Remove the torque converter from the transmission.
RCPH10TLB093AAL 14
16. Remove the cap screws securing the pump in the

transmission.
RCPH10TLB094AAL 15
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17. Loosen the pump from the transmission with two pry
bars.
RCPH10TLB251AAL 16
18. Remove the pump from the transmission.
RCPH10TLB252AAL 17
19. Remove the O-ring from the pump.
RCPH10TLB095AAL 18
20. Remove the seal from the pump.
RCPH10TLB096AAL 19
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21. Tag and remove the lubrication tube.
RCPH10TLB100AAL 20
22. Tag and remove the 4th gear tube (1), 2nd gear tube
(2), 3rd gear tube (3), and the 1st gear tube (4.)
RCPH10TLB101AAL 21
23. Tag and remove the lubrication tube.
RCPH10TLB254AAL 22
24. Loosen the front flange cap screw.
RCPH10TLB596AAL 23
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25. Remove the cap screw and the front flange.
RCPH10TLB102AAL 24
26. Remove the seal from the housing.
RCPH10TLB103AAL 25
Parking Brake
27. Loosen the flange bolt.
RCPH10TLB596AAL 26
28. Remove the flange bolt and washer.
RCPH10TLB868AAL 27
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29. Remove the O-ring and flange.
RCPH10TLB869AAL 28
NOTE: The transmission was removed from the machine for clarity only, it is not necessary to remove the transmis-
sion.
30. Loosen brake housing bolts.
RCPH10TLB871AAL 29
31. Remove bolts (A), and alternately loosen bolts (B) to

release the load of bellville washers.
RCPH10TLB594AAL 30
NOTICE: The housing is under spring pressure, failure to follow these instructions could damage the transmission.
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32. Remove the brake cover from the transmission.
RCPH10TLB872AAL 31
33. Remove and discard the O-ring.
RCPH10TLB873AAL 32
34. Remove back plate.
RCPH10TLB874AAL 33
35. Remove the springs and remove the friction disc.
RCPH10TLB875AAL 34
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36. Remove the reaction plates.
RCPH10TLB876AAL 35
37. Remove the hub.
RCPH10TLB877AAL 36
38. Remove the retaining plate.
RCPH10TLB599AAL 37
39. Remove and discard the O-rings and backup ring

from the retaining plate.
RCPH10TLB600AAL 38
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40. Use CAS2379 to compress the bellville washers, re-

move the retaining ring.
RCPH10TLB601AAL 39
41. Remove the piston from the brake housing.
RCPH10TLB602AAL 40
42. Remove and discard the O-rings and backup rings

from the piston.
RCPH10TLB603AAL 41
43. Remove the bellville washers from the brake hous-

ing.
RCPH10TLB604AAL 42
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44. Remove the seal from the brake housing.
RCPH10TLB605AAL 43
45. Remove and discard the O-ring from the brake hous-
ing.
RCPH10TLB606AAL 44
PTO Shaft
46. Remove the mounting screws for the pump flange.
RCPH10TLB255AAL 45
47. Remove the flange from the transmission.
RCPH10TLB104AAL 46
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48. Remove the PTO shaft from the transmission.
RCPH10TLB256AAL 47
49. Remove the teflon seal ring from the PTO shaft.
RCPH10TLB105AAL 48
50. Remove the snap ring from the PTO shaft.
RCPH10TLB257AAL 49

the PTO shaft.
RCPH10TLB106AAL 50
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Housing separation
52. Remove the cap screws that fasten the front and rear
housings together.
RCPH10TLB258AAL 51
53. Use pry bars in the slots to loosen the front housing
from the rear housing.
RCPH10TLB259AAL 52
54. Attach suitable lifting equipment to the front housing

and remove it from the transmission.
RCPH10TLB260AAL 53
55. Remove and discard the O-rings from the rear hous-
ing.
RCPH10TLB107AAL 54
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56. Pull the input shaft and reverse shaft together.
RCPH10TLB109AAL 55
57. Remove the cap screws and the shield from the 4
wheel drive clutch pack.
RCPH10TLB144AAL 56
58. Attach lifting bracket 380100088 to the shafts, re-

move them from the transmission.
RCPH10TLB145AAL 57
Input shaft
59. Remove the teflon seal ring.
RCPH10TLB110AAL 58
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RCPH10TLB111AAL 59
61. Install a bearing puller under the gear as shown, do

not install the bearing puller between the gear and
the bearing. Insert a shaft protector between the
puller and the end of the input shaft.
RCPH10TLB112AAL 60
RCPH10TLB113AAL 61
63. Remove the spacer.
RCPH10TLB114AAL 62
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64. Remove the gear.
RCPH10TLB115AAL 63
65. Remove the needle bearing.
RCPH10TLB116AAL 64
66. Remove the thrust washer.
RCPH10TLB262AAL 65
67. Remove the roll pin.
RCPH10TLB262AAL 66
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68. Remove the lock ring.
RCPH10TLB117AAL 67
69. Use pry bars to lift and remove the thrust plate.
RCPH10TLB118AAL 68
70. Remove the clutch plates and the clutch discs.
RCPH10TLB119AAL 69
71. Place a mark below a groove on the clutch housing.
RCPH10TLB120AAL 70
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72. Place a mark on each thrust plate and the lock ring.
RCPH10TLB263AAL 71
73. Install the top piece of the CAS2379 special tool (not
shown). Use the three threaded rods and nuts to
fasten the two pieces together.
RCPH10TLB121AAL 72
RCPH10TLB264AAL 73
75. Loosen the nuts and the threaded rods to release the
tension from the spring. Remove the top piece of the
CAS2379 special tool (not shown).
RCPH10TLB121AAL 74
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76. Remove the pressure plate and spring.
RCPH10TLB122AAL 75
77. Remove the sleeve.
RCPH10TLB265AAL 76
78. Use compressed air in the piston pressure port to

remove the piston.
RCPH10TLB123AAL 77
NOTICE: Use an air hose with a safety on/off control nozzle with 2.1 bar (30 psi) maximum at the nozzle. Wear face
protection.
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79. Remove the piston seal rings and backup rings.
RCPH10TLB266AAL 78
80. Turn the clutch housing over, remove the teflon seal
rings.
RCPH10TLB124AAL 79
RCPH10TLB267AAL 80
82. Insert a shaft protector between the puller and the

end of the input shaft. Remove the bearing.
RCPH10TLB125AAL 81
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83. Remove the bearing and thrust washer.
RCPH10TLB126AAL 82
RCPH10TLB303AAL 83
RCPH10TLB127AAL 84
86. Repeat steps 68 to 78 and disassemble the clutch.
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Reverse shaft
end of the reverse shaft. Remove the bearing.
RCPH10TLB128AAL 85
88. Turn the shaft over and insert a shaft protector be-
tween the puller and the end of the reverse shaft.
Remove the bearing.
RCPH10TLB268AAL 86
Primary shaft
89. Remove the teflon seal ring from the primary shaft.
RCPH10TLB272AAL 87
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90. Install a puller on the gear as shown.
RCPH10TLB273AAL 88
91. Remove the bearing and gear.
RCPH10TLB146AAL 89
RCPH10TLB274AAL 90
RCPH10TLB147AAL 91
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RCPH10TLB275AAL 92
RCPH10TLB148AAL 93
96. Remove the needle bearings and thrust washer.
RCPH10TLB149AAL 94
97. Remove the roll pin and spacer.
RCPH10TLB150AAL 95
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98. Drive the thrust plate down away from the lock ring.
RCPH10TLB276AAL 96
RCPH10TLB277AAL 97
100. Remove the thrust plate from the clutch pack.
RCPH10TLB151AAL 98
101. Remove discs and plates from the clutch pack.
RCPH10TLB278AAL 99
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RCPH10TLB152AAL 100
RCPH10TLB279AAL 101
RCPH10TLB152AAL 102
105. Remove the retaining ring and spring.
RCPH10TLB153AAL 103
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RCPH10TLB154AAL 104
107. Use compressed air and remove the piston from the
clutch pack.
RCPH10TLB155AAL 105
RCPH10TLB266AAL 106
RCPH10TLB156AAL 107
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110. Use a puller and remove the bearing from the shaft.
RCPH10TLB157AAL 108
1st, 3rd, and 4th gear shaft

111. Use a puller and remove the bearing.
RCPH10TLB172AAL 109
112. Remove the bushing.
RCPH10TLB173AAL 110
113. Remove the gear and clutch from the shaft.
RCPH10TLB174AAL 111
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114. Push down on the thrust plate.
RCPH10TLB284AAL 112
RCPH10TLB285AAL 113
116. Remove the thrust plate.
RCPH10TLB175AAL 114
RCPH10TLB176AAL 115
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fasten the two pieces together, remove the snap ring.
RCPH10TLB286AAL 116
RCPH10TLB177AAL 117
120. Remove the snap ring, retaining ring, and spring.
RCPH10TLB287AAL 118
121. Use compressed air and remove the piston from the
clutch pack.
RCPH10TLB304AAL 119
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122. Remove the teflon ring and O-ring from the piston.
RCPH10TLB178AAL 120
123. Remove the teflon seal ring and O-ring from the
clutch housing.
RCPH10TLB179AAL 121
124. Use a puller and remove the gear.
RCPH10TLB180AAL 122
125. Remove the needle bearings and spacer.
RCPH10TLB181AAL 123
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126. Remove the O-rings from inside the spacer.
RCPH10TLB182AAL 124
127. Remove the teflon rings from the outside of the

spacer.
RCPH10TLB183AAL 125
RCPH10TLB288AAL 126
RCPH10TLB184AAL 127
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RCPH10TLB071AAL 128
RCPH10TLB310AAL 129
RCPH10TLB185AAL 130
RCPH10TLB289AAL 131
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RCPH10TLB186AAL 132
RCPH10TLB187AAL 133
RCPH10TLB121AAL 134
RCPH10TLB264AAL 135
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RCPH10TLB121AAL 136
RCPH10TLB188AAL 137
140. Used compressed air to remove the piston.
RCPH10TLB305AAL 138
141. Remove the piston and sleeve from the clutch hous-
ing.
RCPH10TLB189AAL 139
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RCPH10TLB266AAL 140
143. Turn the shaft over and remove the teflon seal rings.
RCPH10TLB190AAL 141
RCPH10TLB191AAL 142
RCPH10TLB192AAL 143
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RCPH10TLB193AAL 144
147. Remove the needle bearing and thrust washer.
RCPH10TLB194AAL 145
RCPH10TLB290AAL 146
RCPH10TLB310AAL 147
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RCPH10TLB185AAL 148
RCPH10TLB289AAL 149
RCPH10TLB186AAL 150
RCPH10TLB187AAL 151
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RCPH10TLB121AAL 152
RCPH10TLB264AAL 153
RCPH10TLB121AAL 154
RCPH10TLB188AAL 155
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158. Used compressed air to remove the piston.
RCPH10TLB305AAL 156
159. Remove the piston and sleeve from the clutch hous-
ing.
RCPH10TLB189AAL 157
RCPH10TLB195AAL 158
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4 wheel drive shaft

161. Remove the teflon seals.
RCPH10TLB221AAL 159
162. Use a puller and remove the bearing, remove the

spacer.
RCPH10TLB297AAL 160
RCPH10TLB222AAL 161
RCPH10TLB298AAL 162
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165. Locally fabricate a pipe with notch to access the snap

ring as shown. Remove the snap ring.
RCPH10TLB223AAL 163
166. Remove shims and thrust washer.
RCPH10TLB299AAL 164
167. Remove the bellville washers and spacer.
RCPH10TLB224AAL 165
168. Push down on the thrust plate and remove the lock
ring.
RCPH10TLB225AAL 166
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169. Remove thrust plate, discs, and plates from the

clutch pack.
RCPH10TLB226AAL 167
RCPH10TLB227AAL 168
171. Use a punch and remove the pistons.
RCPH10TLB228AAL 169
172. Remove the O-rings from the piston.
RCPH10TLB603AAL 170
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173. Remove the O-rings from the pistons.
RCPH10TLB229AAL 171
Next operation:
Powershift transmission - Cleaning (21.113)
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Powershift transmission - Cleaning - H-type - 4WD only

Cleaning
1. Clean all parts thoroughly using solvent type clean-
ing fluid. It is recommended that parts be immersed
in cleaning fluid and moved up and down slowly until
all old lubricant and foreign material is dissolved and
parts are thoroughly cleaned .
Bearings
2. Remove bearings from cleaning fluid and strike flat
against a block of wood to dislodge solidified par-
ticles of lubricant. Immerse again in cleaning fluid
to flush out particles. Repeat above operation until
bearings are thoroughly clean. Dry bearings using
moisture-free compressed air. Be careful to direct
air stream across bearing to avoid spinning. Do not
spin bearings when drying. Bearings may be rotated
slowly by hand to facilitate drying process.
Housings
3. Clean interior and exterior of housings, bearing caps,
etc., thoroughly. Cast parts may be cleaned in hot so-
lution tanks with mild alkali solutions providing these
parts do not have ground or polished surfaces. Parts
should remain in solution long enough to be thor-
oughly cleaned and heated. This will aid the evapo-
ration of the cleaning solution and rinse water. Parts
cleaned in solution tanks must be thoroughly rinsed
with clean water to remove all traces of alkali. Cast
parts may also be cleaned with steam cleaner. All
parts cleaned must be thoroughly dried immediately
by using moisture-free compressed air or soft, lint
free absorbent wiping rags free of abrasive materials
such as metal fillings, contaminated oil, or lapping
compound.
Next operation:
Powershift transmission - Inspect (21.113)
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Powershift transmission - Inspect - H-type - 4WD only

Inspection
1. The importance of careful and thorough inspection
of all parts cannot be overstressed. Replacement
of all parts showing indication of wear or stress will
eliminate costly and avoidable failures at a later date.
Bearings
2. Carefully inspect all rollers, cages and cups for wear,
chipping, or nicks to determine fitness of bearings for
further use. Do not replace a bearing cone or cup
individually without replacing the mating cup or cone
at the same time. After inspection, dip bearings in
clean transmission fluid and wrap in clean lint free
cloth or paper to protect them until installed.
Oil Seals, Gaskets, etc.

3. Replacement of spring load oil seals, O-rings, metal
sealing rings, gaskets, and snap rings is more eco-
nomical when uni t is disassembled than premature
overhaul to replace these parts at a future time. Fur-
ther loss of lubricant through a worn seal may result
in failure of other more expensive parts of the assem-
bly. Sealing members should be handled carefully,
particularly when being installed. Cutting, scratch-
ing, or curling under of lip of seal seriously impairs its
efficiency. When assembling new metal type sealing
rings, same should be lubricated with coat of chassis
grease to stabilize rings in their grooves for ease of
assembly of mating members. Lubricate all O-rings
and seals with recommended type transmission fluid
before assembly.
Gears and Shafts

4. Examine teeth on all gears carefully for wear, pit-
ting, chipping, nicks, cracks, or scores. If gear teeth
show spots where case hardening is worn through
or cracked, replace with new gear. Small nicks may
be removed with suitable hone. Inspect shafts and
quills to make certain they are not sprung, bent, or
splines twisted, and that shafts are true.
Housing, Covers, etc.

5. Inspect housings, covers and bearing caps to be cer-
tain they are thoroughly clean and that mating sur-
faces, bearing bores, etc., are free from nicks or
burrs. Check all parts carefully for evidence of cracks
or condition which would cause subsequent oil leaks
or failures.
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Clutches
6. Verify the total thickness of the clutch kit is within the
wear limits, if not, replace the clutch kit. Verify that
all the clutch plates do not appear burned or that the
friction material is not damaged and the splines are
intact. If using new clutch kit, soak the clutch plates
in clean transmission fluid for at least one hour before
assembly.
Forward and Reverse Clutch Kits

Number of clutch plates 6
Number of steel plates 6
Nominal clutch plate thickness 2.40 ± 0.05 MM (0.095 ± 0.002 INCHES)
Maximum clutch plate wear 0.25 MM (0.010 INCHES)
Nominal clutch kit thickness *29.00 - 29.20 MM (1.14 to 1.14 INCHES)
Maximum clutch kit wear 3.0 MM (0.12 INCHES)
*Measured under a load of 163 KG (360 Pound force)
1st Gear Clutch Kit

Maximum clutch kit wear 1.8MM (0.07 INCHES)
2nd Gear Clutch Kit

3rd Gear Clutch Kit

4th Gear Clutch Kit

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4WD Gear Clutch Kit

Maximum clutch kit wear 2.7 MM (0.11 INCHES)
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Powershift transmission - Assemble - H-type -

1. Install new seal rings on clutch piston.
RCPH10TLB603AAL 1
2. Install new O-rings on the pins.
RCPH10TLB229AAL 2
3. Install the pins on the clutch piston.
RCPH10TLB300AAL 3
4. Lubricate the piston and pin O- rings with transmis-

sion fluid.
RCPH10TLB301AAL 4
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5. Use a soft faced hammer and drive the clutch piston

into the clutch housing.
RCPH10TLB230AAL 5
6. Turn the clutch housing over, install the counter disk

in the clutch housing with the tapered edge facing
down.
RCPH10TLB231AAL 6
7. Install the clutch kit starting with a drive plate followed

by a clutch disc, continue to install until all clutch
plates and discs are installed.
RCPH10TLB232AAL 7
8. Install the thrust plate.
RCPH10TLB233AAL 8
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9. Install the retaining ring.
RCPH10TLB234AAL 9
10. Align the clutch discs using a screwdriver then install

the gear.
RCPH10TLB235AAL 10
11. Install the needle bearing and the spacer.
RCPH10TLB236AAL 11
12. Use a suitable driver and install the bearing.
RCPH10TLB237AAL 12
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13. Turn the clutch pack over. Make sure that the disk/
counter disk pack and the piston are seated.
RCPH10TLB238AAL 13
14. Install the spacer and washer.
RCPH10TLB239AAL 14
15. Using a thickness gauge measure the gap between

the washer and lock ring (X).
RCPH10TLB240AAL 15
16. Subtract from X a known value of S1 (S1=1.80MM),

the result is S for the shim thickness required.
(X-1.80)=Shims required.
RCPH10TLB241AAL 16
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17. Select the shim thickness value among the range of

available shims.
RCPH10TLB242AAL 17
NOTE: Make sure there will be a stroke of 1.70 to 1.90 MM after shims are installed.
18. Remove the lock ring and washer from the shaft.
RCPH10TLB243AAL 18
19. Install the bellville washers, the washer must be in-

stalled with the outer rings touching and the inner
rings have a gap.
RCPH10TLB302AAL 19
20. Install the washer and the shim(s) that was deter-
mined in step 16.
RCPH10TLB244AAL 20
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21. Locally fabricate a pipe with notch to access the snap

ring as shown. Compress the bellville washers and
install the lock ring.
RCPH10TLB245AAL 21
RCPH10TLB246AAL 22
23. Use pusher 380001928 to install the teflon seal rings.

Using spacer and protector for the inner ring and
spacer for the outer ring from kit 380040161. Size
the seal rings using sizer 380001427.
RCPH10TLB247AAL 23
24. Mount a dial indicator as shown. Apply 10 Bar (145

psi) to the piston port, the stroke should be between
2.3 to 2.4 MM (0.090 to 0.095 inches).
RCPH10TLB248AAL 24
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1st Gear Clutch Pack

25. On the 1st gear clutch, install a new teflon seal ring
using protector 380100083 and pusher 380001928.
Install a new O-ring.
RCPH10TLB196AAL 25
26. Size the teflon seal ring using sizer 380100084.
RCPH10TLB197AAL 26
27. Install a new teflon seal ring and O-ring on the clutch
piston.
RCPH10TLB198AAL 27
28. Apply clean transmission fluid to the seal rings, install

the piston.
RCPH10TLB291AAL 28
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29. Insert the spring, thrust washer, and snap ring.
RCPH10TLB199AAL 29
30. Place the clutch in CAS2379 special tool (not

shown), and compress the spring.
RCPH10TLB177AAL 30
31. Install the snap ring, make sure the snap ring is prop-
erly seated.
RCPH10TLB286AAL 31
32. Remove the top plate of the spring compressor

CAS2379.
RCPH10TLB200AAL 32
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33. Starting with a reaction plate, install 6 reaction plates

and 6 friction discs. Then install the thrust plate into
the clutch housing.
RCPH10TLB201AAL 33
34. Install the retaining ring, make sure the retaining ring
is properly seated.
RCPH10TLB285AAL 34
35. Apply air pressure to the clutch pack to seat the thrust
plate against the retaining ring and release the air
pressure. Use a feeler gauge and measure the dis-
tance between the thrust plat and the first clutch disc,
a measurement of 1.725 to 2.375 mm (0.068 to 0.094
inches) should be obtained. If the distance is not
within specification, check the clutch assembly.
RCPH10TLB202AAL 35
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4th Gear Clutch Pack

36. Install new O-rings and backup rings on the 4th gear
piston.
RCPH10TLB266AAL 36
37. Apply a thin film of grease on the piston rings.
RCPH10TLB160AAL 37
38. Use 380001926 clutch pack piston installer to protect

the inner seal and install the clutch piston.
RCPH10TLB280AAL 38
39. Install the spring sleeve.
RCPH10TLB161AAL 39
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40. Install the spring and thrust washer.
RCPH10TLB203AAL 40

RCPH10TLB162AAL 41
erly seated.
RCPH10TLB163AAL 42

CAS2379.
RCPH10TLB162AAL 43
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44. Install a new roll pin in the shaft.
RCPH10TLB204AAL 44
45. Apply a thin coat of grease to the bottom of the thrust

washer to keep the washer in place while turning the
shaft.
RCPH10TLB292AAL 45
46. Align the slot in the thrust washer with the roll pin.
RCPH10TLB293AAL 46

and 9 friction discs.
RCPH10TLB205AAL 47
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48. Install the needle bearing and the thrust plate.
RCPH10TLB206AAL 48
is properly seated.
RCPH10TLB207AAL 49
pressure. Align the clutch disc splines.
RCPH10TLB208AAL 50
51. Use a feeler gauge and measure the distance be-

tween the thrust plat and the first clutch disc, a mea-
surement of 1.50 to 1.95 mm (0.060 to 0.075 inches)
should be obtained. If the distance is not within spec-
ification, check the clutch assembly.
RCPH10TLB209AAL 51
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52. Install the clutch hub into the clutch pack, make sure
the clutch hub seats completely.
RCPH10TLB210AAL 52
Assembling 1st Gear Onto The Shaft

53. Put 1st gear clutch hub onto the shaft.
RCPH10TLB294AAL 53
54. Put 1st gear clutch pack onto 1st gear clutch hub,
make sure the clutch hub seats completely.
RCPH10TLB174AAL 54
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55. Use a suitable driver and install the bushing onto the
shaft, install the needle bearing.
RCPH10TLB211AAL 55
56. Remove the old teflon seal rings from the bushing.
RCPH10TLB212AAL 56
57. Install new teflon seal rings on the bushing with

protector and shim set 380100085, use pusher
380001928.
RCPH10TLB307AAL 57
58. Size the teflon seal rings using 380100086 sizer.
RCPH10TLB308AAL 58
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59. With the reference marks up, install the bushing into
the clutch pack.
RCPH10TLB213AAL 59
60. Use a suitable driver and install the bushing onto the
shaft, install the needle bearing.
RCPH10TLB214AAL 60
RCPH10TLB215AAL 61
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3rd Gear Clutch Pack

62. Install new O-rings and backup rings on the piston.
RCPH10TLB266AAL 62
RCPH10TLB160AAL 63

RCPH10TLB280AAL 64
RCPH10TLB216AAL 65
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RCPH10TLB295AAL 66

RCPH10TLB162AAL 67
erly seated.
RCPH10TLB163AAL 68

CAS2379.
RCPH10TLB162AAL 69
47365539 08/07/2012
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70. Install a new roll pin.
RCPH10TLB296AAL 70

RCPH10TLB205AAL 71
72. Install the thrust plate.
RCPH10TLB206AAL 72
is properly seated.
RCPH10TLB207AAL 73
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RCPH10TLB281AAL 74

RCPH10TLB209AAL 75
76. Install the thrust washer and roller bearing.
RCPH10TLB217AAL 76
77. Install the clutch hub, make sure the clutch hub seats
completely.
RCPH10TLB218AAL 77
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78. Install the thrust washer.
RCPH10TLB219AAL 78
RCPH10TLB220AAL 79
80. Install the teflon seal rings starting with the inner most
ring first. Use protector and shims as required from
380040161 and pusher 380001928. Size the seal
rings using sizer 380001427.
RCPH10TLB140AAL 80
2nd Gear Clutch Pack

RCPH10TLB158AAL 81
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82. Install the teflon seal ring. Use protector and shims
as required from 380040161 and pusher 380001928.
Size the seal rings using sizer 380001427.
RCPH10TLB159AAL 82
RCPH10TLB266AAL 83
RCPH10TLB160AAL 84

RCPH10TLB280AAL 85
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RCPH10TLB216AAL 86
RCPH10TLB295AAL 87

RCPH10TLB162AAL 88
erly seated.
RCPH10TLB163AAL 89
47365539 08/07/2012
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CAS2379.
RCPH10TLB162AAL 90

RCPH10TLB164AAL 91
92. Install the spacer and the roll pin.
RCPH10TLB165AAL 92
93. Align the slot on the thrust washer with the roll pin,
install the thrust washer and the needle bearing.
RCPH10TLB166AAL 93
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94. Install the thrust plate and drive it down evenly to the
clutch disc.
RCPH10TLB167AAL 94
is properly seated.
RCPH10TLB168AAL 95
RCPH10TLB281AAL 96
97. Install the clutch hub, make sure the clutch hub seats
completely.
RCPH10TLB169AAL 97
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98. Install the roll pin.
RCPH10TLB170AAL 98
install the thrust washer and the snap ring.
RCPH10TLB282AAL 99

RCPH10TLB209AAL 100
101. Install the gear with the large hub down, use a suit-
able driver and install the bearing.
RCPH10TLB283AAL 101
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102. Install the teflon seal rings starting with the inner most
ring first. Use protector and shims as required from
380040161 and pusher 380001928. Size the seal
rings using sizer 380001427.
RCPH10TLB171AAL 102
Reverse Shaft
103. Use a suitable driver and install a bearing on one end
of the shaft.
RCPH10TLB141AAL 103
104. Turn the shaft over and install a bearing on the other
end of the shaft.
RCPH10TLB142AAL 104
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Forward and Reverse Clutch Packs

RCPH10TLB266AAL 105
RCPH10TLB160AAL 106

RCPH10TLB280AAL 107
RCPH10TLB216AAL 108
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RCPH10TLB295AAL 109

RCPH10TLB162AAL 110
erly seated.
RCPH10TLB163AAL 111

CAS2379.
RCPH10TLB162AAL 112
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113. Install the roll pin.
RCPH10TLB129AAL 113
install the thrust washer.
RCPH10TLB130AAL 114
115. Install the needle bearing.
RCPH10TLB131AAL 115
116. Place the clutch hub on a bench, install the thrust

plate on the hub.
RCPH10TLB132AAL 116
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117. Starting with a friction disc, install 6 friction discs and

6 reaction plates.
RCPH10TLB133AAL 117
118. Install the clutch pack in the clutch housing.
RCPH10TLB134AAL 118
is properly seated.
RCPH10TLB269AAL 119
120. Install the spacer.
RCPH10TLB114AAL 120
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121. Heat the bearing to 80° to 100° C (176° to 212° F),

use a suitable driver and install the bearing.
RCPH10TLB135AAL 121
122. Install the snap ring.
RCPH10TLB136AAL 122
123. Place the 380001429 spacer into the 380001428 ex-

pander/protector.
RCPH10TLB826AAL 123
124. Slide the expander/protector and spacer onto the in-

put shaft. Heat the Teflon sealing ring to 80° to 100°
C (176° to 212° F). Install the Teflon sealing ring onto
the 380001428 expander/protector.
RCPH10TLB829AAL 124
47365539 08/07/2012
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groove in the shaft. Remove the pusher, expander/
protector, and spacer from the shaft.
RCPH10TLB830AAL 125

RCPH10TLB840AAL 126
from the shaft.
RCPH10TLB827AAL 127

RCPH10TLB137AAL 128
129. Turn the shaft over and repeat steps 104to 118and
assemble the other clutch pack.
47365539 08/07/2012
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130. Install the roll pin, align the slot on the thrust washer
with the roll pin, install the thrust washer.
RCPH10TLB270AAL 129
RCPH10TLB138AAL 130
RCPH10TLB139AAL 131

pander/protector.
RCPH10TLB821AAL 132
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134. Slide the 380001933 expander/protector and the

spacer onto the shaft. Heat the Teflon sealing ring
to 80° to 100° C (176° to 212° F). Install the Teflon
sealing ring onto the expander/protector.
RCPH10TLB831AAL 133

groove in the shaft. Remove the pusher, protector,
and spacer from the shaft.
RCPH10TLB838AAL 134

RCPH10TLB839AAL 135
from the shaft.
RCPH10TLB840AAL 136
47365539 08/07/2012
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pander/protector.
RCPH10TLB822AAL 137
139. Slide the expander/protector and the spacer onto the

shaft. Heat the Teflon sealing ring to 80° to 100° C
(176° to 212° F). Install the Teflon sealing ring onto
the expander/protector.
RCPH10TLB832AAL 138

RCPH10TLB837AAL 139

RCPH10TLB839AAL 140
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from the shaft.
RCPH10TLB840AAL 141

pander/protector.
RCPH10TLB823AAL 142

RCPH10TLB833AAL 143

RCPH10TLB836AAL 144
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RCPH10TLB839AAL 145
from the shaft.
RCPH10TLB840AAL 146

pander/protector.
RCPH10TLB824AAL 147

RCPH10TLB834AAL 148
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RCPH10TLB835AAL 149

RCPH10TLB839AAL 150
from the shaft.
RCPH10TLB840AAL 151
Transmission Housings
153. Lubricate the bores of the transmission housing that
house teflon sealing rings.
RCPH10TLB143AAL 152
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154. Attach lifting bracket 380100088 to the three shafts

as shown, install the shafts into the housing.
RCPH10TLB145AAL 153
155. Install the 4WD clutch cover as shown, apply Loctite

542 to the threads and torque cap screws to 50 Nm
(37 pound feet).
RCPH10TLB144AAL 154
156. Install the forward and reverse clutch pack and the
reverse shaft into the housing as an assembly.
RCPH10TLB109AAL 155
157. Start the bearing of the reverse shaft into its bore in
the housing and mesh the gears at the same time.
RCPH10TLB271AAL 156
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158. Apply a thin coat of Loctite 510 to the mating surface

of the transmission housing.
RCPH10TLB261AAL 157
159. Install new O-rings in the housing.
RCPH10TLB107AAL 158
160. Lubricate the bores of the front transmission housing

that house teflon sealing rings.
161. Attach lifting equipment to the front housing, lower
the front housing onto the rear housing.
RCPH10TLB260AAL 159
NOTE: Do not bind the shafts to prevent damaging the teflon seal rings.
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162. Install and hand tighten all of the transmission hous-

ing cap screws.
RCPH10TLB108AAL 160
163. Torque the housing cap screws to 50 Nm (37 pound

feet).
RCPH10TLB258AAL 161
PTO Shaft
164. Slide the expander/protector onto the pump drive
shaft.
RCPH10TLB842AAL 162

380001428 expander/protector.
RCPH10TLB843AAL 163
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RCPH10TLB844AAL 164

RCPH10TLB845AAL 165
from the shaft.
RCPH10TLB846AAL 166
169. Install the bearing and snap ring on the PTO shaft.
170. Put the PTO shaft into the transmission.
RCPH10TLB256AAL 167
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of the pump mount and rear cover. Prepare the seal-
ing surface by rubbing with a 3M Scotch-Brite fiber
pad or equivalent. DO NOT use steel wool or any-
thing that can leave material on the sealing surface.
Wipe the sealing surface with Loctite Safety Solvent
or equivalent. Apply a layer of Loctite 518 or Super
bond 539 to the sealing surface.
172. Clean the housing, use Loctite 518 sealer on the mat-
ing surfaces.
RCPH10TLB104AAL 168
173. Install the pump mount on the rear housing, torque

bolts to 50 Nm (37 pound-feet).
RCPH10TLB255AAL 169
Parking Brake
174. Install a new O-ring on the brake housing.
RCPH10TLB607AAL 170
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175. Install the bellville washers as shown.
RCPH10TLB595AAL 171
176. Install the backup ring, install the seal ring.
RCPH10TLB608AAL 172
NOTE: Make sure that the seal ring does not twist during installation.
177. Lubricate the piston seals with transmission fluid, in-
stall the piston into the brake housing.
RCPH10TLB602AAL 173
178. Use CAS2379 and compress the bellville washers,

install the retaining ring.
RCPH10TLB601AAL 174
NOTICE: Make sure the retainer is properly seated before removing spring compressor.
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179. Install new O-rings and backup ring in the retaining

plate.
RCPH10TLB600AAL 175
180. Lubricate the O-rings on the retaining plate, install

the plate into the brake housing.
RCPH10TLB599AAL 176
RCPH10TLB877AAL 177
RCPH10TLB876AAL 178
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RCPH10TLB875AAL 179
RCPH10TLB874AAL 180
RCPH10TLB873AAL 181
RCPH10TLB872AAL 182
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sion. Torque the bolts to 50 Nm (37 pound feet).
RCPH10TLB871AAL 183
RCPH10TLB869AAL 184
RCPH10TLB868AAL 185
190. Torque bolt to 139 Nm (103 pound feet).
RCPH10TLB870AAL 186
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Lubrication and Clutch Tubes

191. Install tubes and torque to 30 Nm (22 pound-feet).
RCPH10TLB254AAL 187
Pump
RCPH10TLB095AAL 188
193. Install the seal.
RCPH10TLB097AAL 189
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194. When installing the pump align the pump holes.
RCPH10TLB098AAL 190
195. Lubricate the teflon seal ring with clean transmission

fluid.
RCPH10TLB253AAL 191
196. Lubricate the O-ring with clean transmission fluid.
RCPH10TLB099AAL 192
197. Push the pump into position.
RCPH10TLB252AAL 193
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198. Install and torque bolts to 23 Nm (17 pound-feet).
RCPH10TLB094AAL 194
199. Install the torque converter.
RCPH10TLB093AAL 195
200. Install a new suction filter.
RCPH10TLB250AAL 196
201. Install the cover and torque the bolts to 23 Nm (17

pound-feet).
RCPH10TLB082AAL 197
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202. Install and torque drain plugs to 80 Nm (59 pound-

feet).
RCPH10TLB081AAL 198
203. Install and torque the filter bypass to 23 Nm (17

pound-feet).
RCPH10TLB085AAL 199
204. Install and torque the speed sensor to 50 Nm (37

pound-feet).
RCPH10TLB090AAL 200
205. Install and torque the thermostat to 30 Nm (22 pound-

feet).
RCPH10TLB091AAL 201
206. Install a new oil filter.
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207. Fill transmission with approved fluid, see specifica-

tions.
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Powershift transmission - View Troubleshooting and Monitoring

EST Parameters
When troubleshooting Powershift S-type transmission
shifting problems or fault codes, the EST should be the first
tool used to diagnose problems. By monitoring parameters
with the EST combined with other external tests, it can
quickly be determined whether the problem is electrical,
hydraulic, or mechanical in nature.
Connect the EST and monitor the following functions:
• Selected Gear: This is the gear which the
TRAX controllers interprets that has been
specified by the operator through the FNR
switch gear command 01 & 02.
• Current Gear: This is the gear that the TRAX
controller sees the transmission is in.
• S-type – Gear 1 & 2 Analog voltage: input from
the resistor network
• S-type – Gear 3 & 4 Analog voltage: input from
the resistor network
• S-type – Gear Command 01 Status: input from
FNR switch
• S-type – Gear Command 02 Status: input from
FNR switch / Comfort Steer Cutout relay
• S-type – Gear SW1 logical status: TRAX inter-
pretation of gear switch position based on ana-
log voltages from resistor network
• S-type – Solenoid valve 1 Status: TRAX con-
troller is sending current to this solenoid.
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RCPH11TLB007FAL 1
EST screen shot showing parameters being monitored.
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Powershift transmission - Tool connection Test Port and

Component Locations, H-Type
RCPH11TLB006GAL 1
Left Side View
(1) Valve body (5) 1st check port

(2) Oil filter bypass valve (6) 2nd check port
(3) Speed sensor (7) Lubrication check port
(4) 4th check port (8) Torque converter inlet pressure test port
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RCPH11TLB007GAL 2
Front View
(9) Spin on Filter (11) Dip stick port

(10) Oil pump (3) Speed sensor
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RCPH11TLB008GAL 3
Right Side View
(12) Thermostat (16) 3rd check port

(13) Oil return from cooler (17) Drain plug
(14) Oil port to cooler (18) ID plate
(15) Suction filter
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RCPH11TLB009GAL 4
Rear View
(19) Booster port to vehicle brakes (22) Oil return port from vehicle brakes
(20) Hydraulic pump mount (23) Park brake pressure test port
(21) SAHR parking brake housing (24) Park brake release solenoid
(3) Speed sensor
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RCPH11TLB010GAL 5
Top View
(25) Pressure sensor (29) Reverse clutch test port

(26) Breather (30) Oil check port
(27) Lube pressure test port (31) Differential lock test port
(28) Forward clutch test port
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Powershift transmission - Tool connection Test Port and

Component Locations, S-Type
RCPH11TLB014GAL 1
Top Right View
(1) Cooler OUT (7) Charge pressure test port

(2) Cooler IN (8) Cooler IN test port
(3) Breather (9) Oil return port
(4) Forward test port (10) Oil pressure ports
(5) Reverse test port (11) Threaded holes, M12–1.75
(6) HDL out
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RCPH11TLB015GAL 2
Left Side View
(12) TC IN test port (15) SAHR brake pressure switch

(13) Temperature sensor (16) SAHR brake pressure test port
(14) Speed sensor (17) SAHR brake control valve
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RCPH11TLB012GAL 3
Right Side View
(18) 1st gear switch (24) 2nd test port

(19) 3rd gear switch (25) Return oil from service brake
(20) 2nd gear switch (26) 3N4 test port
(21) 4th gear switch (27) 3rd test port
(22) SAHR 4WD test port (28) 1N2 test port
(23) 4th test port (29) 1st test port
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RCPH11TLB013GAL 4
Top Left View
(30) Charge pressure sensor (32) Transmission harness connector

(31) Pressure regulator valve
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Powershift transmission - Warm up Heating the Oil

1. Check the oil level and type before proceeding.
2. Activate the parking brake.
4. Place the gear selector into 4th gear.
5. Put the FNR selector in forward.
6. Run the engine up to 1600 RPM ± 100 RPM for a
period of 30 seconds.
NOTE: Do not exceed 30 seconds.
7. Reduce the engine speed to low idle and place the
FNR lever in neutral for 15 seconds.
8. Repeat steps 6 and 7 until the oil temperature is be-
tween 78 °C (172 °F) and 82 °C (180 °F).
9. Perform an engine stall test before proceeding. Re-
fer to Engine - Speeds stall test normal (all mod-
els) (10.001).
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Transmission housing - Disassemble - S-Type (SPS Power Synchro)

- Front housing
1. Remove the cap screws that fasten the front and rear
housings together.
RCPH10TLB258AAL 1
2. Remove bearing snap ring
RCPH10TLB176ACL 2
3. Untighten and remove flange retaining screw. Use a

screwdriver and two screws to avoid flange rotation.
RCPH10TLB110ACL 3
4. Remove washer.
RCPH10TLB111ACL 4
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5. Remove flange (1)and O-ring (2).
RCPH10TLB112ACL 5
6. Remove the three cap screws.
RCPH10TLB113ACL 6
RCPH10TLB114ACL 7
RCPH10TLB115ACL 8
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9. Remove the seal from the cover.
RCPH10TLB116ACL 9
10. Remove screws.
RCPH10TLB132ACL 10
11. Remove screws.
RCPH10TLB117ACL 11
12. Use lever to remove the front half housing. Lift the
front half housing by means of two hooks.
RCPH10TLB133ACL 12
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13. Use a plastic mallet to detach the half housing if nec-

essary.
RCPH10TLB200ACL 13
NOTE: Do not lift the shafts of the transmission; remove the shaft from relative seats could produce seal rings damage.
14. The outer rings of the bearings for the primary shaft
(1)and for the secondary shaft (2)can stay with ei-
ther the shafts or the front housing. Remove the two
bearings.
RCPH10TLB119ACL 14
15. Remove the bearings of the primary shaft (1), and

secondary shaft (2) from the front half housing and
assemble all the bearings on the relative shaft.
RCPH10TLB250ACL 15
NOTE: Do not overturn the bearings; the bearings must be assembled in the same position.
16. Remove the 4WD shaft (1) with a plastic mallet.
RCPH10TLB206ACL 16
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17. Remove bearing.
RCPH10TLB118ACL 17
18. Remove the input shaft (1). Remove the idler shaft
(2).
RCPH10TLB177ACL 18
19. Remove the four-wheel drive clutch tube (1)from the

front housing only if the front housing must be re-
placed or if the tube is leaking or damaged.
RCPH10TLB044ACL 19
20. Replace O-rings (N° 6), if necessary.

21. Close all oil pipe holes with rubber plugs.
RCPH10TLB249ACL 20
Next operation:
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Transmission housing - Assemble (21.113)
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Transmission housing - Assemble - S-Type (SPS Power Synchro) -

Front housing
NOTE: Thoroughly inspect the transmission prior to assembly.
1. Remove the oil from the rear housing edge. Examine
with care the housing and the inner parts to check
the presence of any impurity (dirty, file dust or chips).
Clean with care to remove all the impurities.
RCPH10TLB161ACL 1
2. Remove all the old sealant from the rear housing cou-
pling surface with a suitable tool.
RCPH10TLB202ACL 2
3. Use a sealant solvent.
RCPH10TLB201ACL 3
4. Clean the O-Rings seats. Degrease and dry the cou-

pling surface of the rear housing.
RCPH10TLB203ACL 4
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5. Apply the prescribed sealant on the coupling surface

of the rear housing .
RCPH10TLB204ACL 5
6. Spread the sealant in a film of uniform thickness.
RCPH10TLB162ACL 6
NOTE: Do not put the sealant in the O-Ring seats.

7. Clean the O-Ring seats.
RCPH10TLB205ACL 7
8. Assemble the 6 O-rings.
RCPH10TLB254ACL 8
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9. Push the 6 O-Rings into their seats.
RCPH10TLB254ACL 9
10. Clean and assemble the 4WD shaft.
RCPH10TLB719AAL 10
11. Use clean transmission oil to lubricate the bearing

for the primary shaft (1)and the bearing for the sec-
ondary shaft (2). Install the bearings.
RCPH10TLB250ACL 11
12. If the four-wheel drive clutch tube (1)was removed

from the front housing, install the four-wheel drive
clutch tube. Torque to Powershift transmission -
Torque (21.113).
RCPH10TLB044ACL 12
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13. Install the front half housing on the rear half housing.
Make sure that the bearings on the shafts go straight
into the bores in the front half housing. Push the
front half housing all the way down on the rear half
housing.
RCPH10TLB169ACL 13
14. Assemble screws (16). Torque to 100 N·m (73.8 lb

ft).
RCPH10TLB259AAL 14
15. Assemble screws (16). Tightening torque 50 N·m

(36.9 lb ft).
RCPH10TLB258AAL 15
16. Use clean transmission oil to lubricate the bearing

for the 4WD shaft. Install the bearing (1) on the 4WD
shaft. Use suitable driver.
RCPH10TLB089ACL 16
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17. The seal ring must be installed to the end of its seat
into the cover, if necessary push the seal ring to the
end of its seat with a suitable tool and a hammer.
RCPH10TLB115ACL 17
18. Use a suitable tool and a hammer to install a new

seal (1) in the cover (2).
RCPH10TLB120ACL 18
19. Use a suitable tool to push the seal just to the end.
After the assembly, lubricate the seal ring lip with
grease
RCPH10TLB013ACL 19
20. Assemble the O-Ring.
RCPH10TLB115ACL 20
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21. Install the cover in the front housing.
RCPH10TLB114ACL 21
22. Install the three cap screws which fasten the cover
to the front housing. Tightening torque Powershift
transmission - Torque (21.113).
RCPH10TLB113ACL 22
23. Install a new O-ring in the four-wheel drive flange.
RCPH10TLB112ACL 23
24. Install the four-wheel drive flange on the four-wheel

drive shaft.
RCPH10TLB121ACL 24
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RCPH10TLB111ACL 25
26. Assemble screw. Use screwdriver to avoid flange ro-

tation. Tightening torque Powershift transmission
- Torque (21.113).
RCPH10TLB110ACL 26
27. Assemble the bearing snap ring. Assemble the

oil pump Powershift transmission - Assemble
(21.113).
RCPH10TLB176ACL 27
28. Assemble the groups.
RCPH10TLB175ACL 28
Next operation:
Shaft assemblies - Disassemble (21.155)
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Powershift transmission - Testing Machine Will Not Move, H-Type

and S-Type
fer to Powershift transmission - step. rect. Check for leaks. Fill the trans-
General specification (21.113). mission oil to the proper level. Re-
Does the SAHR parking brake re- Yes, the SAHR parking brake does No, the SAHR parking brake does
lease? release. Go to next step. not release. Check transmission oil
pressure and electrical supply to the
solenoid. Repair as required.
Check for broken universal joint or The drive shaft and universal joint The drive shaft or universal joint is
drive shaft. are free from damage. Go to next damaged. Repair as required.
step.
Raise the rear wheels off the ground. The drive shaft turns when the trans- The drive shaft does not turn. Check
Check mission directional control lever the electrical connections to the
Verify that the drive shaft turns when (FNR) is moved into Forward or Re- transmission. Verify that there is
the transmission directional control verse. Go to next step. power to the clutch solenoids. Check
lever (FNR) is moved into Forward or fuse F-024.
Reverse.
Check transmission pressure and The transmission pressures and
pump flow. pump flow are within specifications. The transmission pressures
and pump flow are not within
specifications. Possible causes
include:
• Cold oil by-pass valve may be
stuck or damaged.
• Faulty pressure regulator.
• Faulty transmission oil pump.
Repair or replace as required.
Check the converter IN pressure. The converter IN pressure is within The converter IN pressure is not
specifications. Go to next step. within specifications. Check the
transmission control valve. Repair
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Check the Forward and Reverse so- The regulated clutch pressures are The regulated clutch pressures are
lenoid valve. within the specified range. Go to not within the specified range. Re-
next step. fer to Forward and Reverse solenoid
troubleshooting in the Service Man-
ual.
Check regulated clutch pressure. The regulated clutch pressure is
within specifications. The regulated clutch pressure is
not within specifications. Possible
causes include:
• Pressure remains zero in For-
ward, Neutral and Reverse.
Check the control valve.
• Pressure is low, check the con-
trol valve.
• Pressure is Forward and Re-
verse are the same. Check the
control valve.
• Forward and Reverse pres-
sures are different. Inspect the
individual clutch circuits.
Powershift transmission - Testing Loss of Power, H-Type and

S-Type
Verify that there is not a buildup of The wheel wells and drive train are There is mud and debris in the wheel
mud or foreign material on the inside free of mud and debris. Go to next well or along the drive train. Remove
of the wheel wells or along the drive step. all mud and debris. If the problem
train. still exists, go to next step.
Perform a stall test according to the The engine performed to specifica- The engine did not perform to speci-
instructions in Power Shuttle trans- tions during the stall test. Go to next fications during the stall test. Repair
mission - Test — Checking Regu- step. the engine as required.
lated Clutch Pressure (21.112).
Check the regulated clutch pressure. The pressures are within specifica- The pressure is out of range. In-
Refer to Power Shuttle transmis- tions. Go to Power Shuttle trans- spect the input shaft sealing rings
sion - Test — Checking Regulated mission - Testing — Machine Will and clutch piston seals. Inspect the
Clutch Pressure (21.112) Not Move (21.112) forward and reverse clutch friction
discs. Repair or replace as required.
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Powershift transmission - Testing Wheels Rotate When Vehicle is

Raised, H-Type and S-Type
Verify the proper transmission oil The oil type is correct. Go to next The transmission oil type is not cor-
type. Refer to Powershift trans- step. rect. Drain and fill the transmission
mission - General specification with the proper oil type. Refer to
(21.113). Refer to Transmission Transmission Fluid Level in the Op-
Fluid Level in the Operator’s Man- erator’s Manual.
ual.
Is the oil temperature low (high oil The oil is at the proper operating The oil temperature is low. Refer to
viscosity) temperature, between 78 °C (172.4 the warm-up procedure, Powershift
°F) and 82 °C (179.6 °F). Go to next transmission - Warm up Heating
step. the Oil (21.113).
Verify that the control valve is allow- The control valve is not allowing The control valve is allowing pres-
ing pressure to the clutches while in pressure to the clutches while in sure to the clutches while in neutral.
the neutral position. neutral. Stop. Replace or repair as required.
Powershift transmission - Testing Transmission Oil is Too Hot,

H-Type and S-Type
The oil level is correct. Go to next The transmission oil level is not cor-
Verify the transmission oil level. Re-
fer to Powershift transmission -step. rect. Check for leaks. Fill the trans-
The transmission oil cooler is clean. The transmission oil cooler is dirty
Check the transmission oil cooler for
Go to next step.
air flow restrictions. Clean the exte- and there are air flow restrictions.
rior of the transmission oil cooler as Clean the exterior of the transmis-
required. sion oil cooler as required. Go to the
next step if the problem still exists.
Check the converter IN pressure. The converter IN pressure is within The converter pressure is not within
Refer to Power Shuttle transmis- specifications. Go to next step. specifications. Refer to Power
sion - Test — Checking Converter Shuttle transmission - Testing —
In Pressure (21.112) Machine Will Not Move (21.112)
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Check the converter OUT pressure. The converter OUT pressure is The converter OUT pressure is not
Refer to Power Shuttle transmis- within specifications. Go to next within specifications. Refer to Pow-
sion - Test — Checking Converter step. ershift transmission - Testing Ma-
Out Pressure (21.112). chine Will Not Move, H-Type and
S-Type (21.113)
Check the lube pressure. Refer to The lube pressure is within specifica-
Powershift transmission - Tool tions. STOP. The pressure is not within
connection Test Port and Compo- specifications. If the torque
nent Locations, H-Type (21.113). converter pressure is high and
the lube pressure is low, possible
causes include:
• Restriction in the oil cooler.
Replace the oil cooler. The
transmission oil cooler cannot
be flushed or cleaned out. The
complete oil cooler must be re-
placed is a restriction is found.
• The oil cooler circuit is re-
stricted. Inspect the oil cooler
circuit and repair as required.
Powershift transmission - Testing Noisy Transmission, H-Type and

S-Type
Verify that the torque converter is not The torque converter is not dam- The torque converter is damaged.
damaged. aged. Go to next step. Repair or replace as required.
Verify that the oil pump is not dam- The oil pump is not damaged. Go to The oil pump is damaged. Repair or
aged. next step. replace as required.
Check for seized or broken gears, The gears, shafts, bearings, etc. are A gear, shaft, bearing, etc. is seized
shafts, bearings, etc. not seized or broken. or broken. Repair or replace as re-
quired.
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Powershift transmission - Testing Irregular Clutch Activation,

H-Type and S-Type
The clutch pressure is in the speci- The clutch pressure is not in the
Check clutch pressure. Is the pres-
fied range. Go to next step.
sure in the specified range? Refer to specified range. Inspect the modu-
Powershift transmission - General lation spool and piston for sticking
specification - H-type (21.113) and damage. Repair or replace as
required.
Check for fault codes on the Trax There are no fault codes associated The Trax Controller does have active
Controller. with the Trax Controller. Check the fault codes. Troubleshoot and repair
electrical connections to the clutch as required.
solenoids.
Powershift transmission - Testing Gear Remains Engaged, H-Type

and S-Type
The clutch pressure is in the speci- The clutch pressure is not in the
Check clutch pressure. Is the pres-
fied range. Go to next step.
sure in the specified range? Refer to specified range. Inspect the modu-
Powershift transmission - General lation spool and piston for sticking
specification - H-type (21.113) and damage. Repair or replace as
required.
solenoids.
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Powershift transmission - Testing Will Not Go Into 4WD, H-Type

and S-Type
Check for broken universal joint or The universal joint and front drive The universal joint or front drive shaft
front drive shaft. shaft are functioning properly. Go to is in need of repair. Repair or replace
next step. as required.
Raise the machine off of the ground. The front drive shaft turns freely The front drive shaft does not turn
All four wheels should be able to ro- when the transmission control is in when the transmission control is in
tate freely. gear but the axle does not. There is gear. Go to next step.
Check a problem in the front axle. Repair
Verify that the front and rear drive as required.
shafts turn when the transmission
directional control lever (FNR) is
moved into Forward or Reverse.
solenoids.
Powershift transmission - Testing Problem in the Parking Brake

System, H-Type and S-Type
Does the parking brake release? The parking brake will release. Refer
to Parking brake disks - Inspect Check the electrical and hydraulic
(33.110) and Parking brake disks - circuits.
Test (33.110). If the parking brake • Check the differential lock
will not hold the machine, repair or pressure. The differential lock
replace the disc brakes. and the parking brake are on
the same pressure circuit. If
the differential lock pressure
is within specifications, re-
fer to Powershift transmis-
sion - General specification
- H-type (21.113).
• Check fuses, replace fuses as
required.
• Check switch operation, repair
• Measure the solenoid resis-
tance. The resistance should
be approximately 9.8 Ω at 20
°C (68 °F). Replace the sole-
noid as required.
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Index
Transmission - 21

Powershift transmission - Assemble - H-type - . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Powershift transmission - Assemble - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Powershift transmission - Assemble - S-type (SPS power synchro) Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Powershift transmission - Cleaning - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Powershift transmission - Disassemble - H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Powershift transmission - Disassemble - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Powershift transmission - Disassemble - S-type (SPS power synchro)- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Powershift transmission - Exploded view - H-type - 1st, 3rd, 4th gear shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Powershift transmission - Exploded view - H-type - transmission assembly - 4 wheel drive shaft . . . . . . . . . . . . . 32
Powershift transmission - Exploded view - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Powershift transmission - Exploded view - S-Type (SPS Power Synchro) - Filters . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Powershift transmission - Exploded view - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . 42
Powershift transmission - Exploded view - S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . 46
Powershift transmission - Exploded view - S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . 40
Powershift transmission - Exploded view - S-Type (SPS Power Synchro) - Rear cover . . . . . . . . . . . . . . . . . . . . . 44
Powershift transmission - Exploded view - S-Type (SPS Power Synchro) - Shafts B - C . . . . . . . . . . . . . . . . . . . . 50
Powershift transmission - Exploded view - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . 54
Powershift transmission - Exploded view - S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . 38
Powershift transmission - Exploded view - S-type (SPS Power Synchro) - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . 36
Powershift transmission - Exploded view - S-type (SPS power synchro) - Shaft A - D . . . . . . . . . . . . . . . . . . . . . . . 48
Powershift transmission - Exploded view -S-type (SPS power synchro) - transmission assembly - 4 wheel drive
shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Powershift transmission - General specification - S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Powershift transmission - General specification Trax Controller Pin Out Guide, S-Type Transmission . . . . . . . . . 26
Powershift transmission - General specification - H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Powershift transmission - General specification - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Powershift transmission - Hydraulic schema H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Powershift transmission - Hydraulic schema S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Powershift transmission - Inspect - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Powershift transmission - Install - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Powershift transmission - Overview S-Type Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Powershift transmission - Remove - Powershift H-type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Powershift transmission - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Powershift transmission - Special tools - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Powershift transmission - Testing Gear Remains Engaged, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . 207
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Powershift transmission - Testing Irregular Clutch Activation, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . 207
Powershift transmission - Testing Loss of Power, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Powershift transmission - Testing Machine Will Not Move, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Powershift transmission - Testing Noisy Transmission, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Powershift transmission - Testing Transmission Oil is Too Hot, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . 205
Powershift transmission - Testing Wheels Rotate When Vehicle is Raised, H-Type and S-Type . . . . . . . . . . . . . 205
Powershift transmission - Testing Will Not Go Into 4WD, H-Type and S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Powershift transmission - Testing Problem in the Parking Brake System, H-Type and S-Type . . . . . . . . . . . . . . . 208
Powershift transmission - Tool connection Test Port and Component Locations, H-Type . . . . . . . . . . . . . . . . . . . 180
Powershift transmission - Tool connection Test Port and Component Locations, S-Type . . . . . . . . . . . . . . . . . . . 185
Powershift transmission - Torque - H-type - 4WD only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Powershift transmission - Torque - S-type (SPS Power Synchro) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Powershift transmission - View Troubleshooting and Monitoring EST Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 178
Powershift transmission - Warm up Heating the Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Transmission housing - Assemble - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . . . . 196
Transmission housing - Disassemble - S-Type (SPS Power Synchro) - Front housing . . . . . . . . . . . . . . . . . . . . . 190
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Transmission - 21
Power Shuttle transmission external controls - 134
580N
580SN WT
580SN
590SN
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Contents
Transmission - 21
FUNCTIONAL DATA
Transmission control valve

Exploded view - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE

Disassemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassemble - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspect - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assemble - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Transmission - Power Shuttle transmission external controls
Transmission control valve - Exploded view - Four wheel drive

valve (if equipped)
Four wheel drive valve (if equipped)
1. Bolt 5. Check valve 9. Solenoid coil
2. Plug 6. Gasket 10. Connector
3. Copper washer 7. O-rings 11. Nut
4. Solenoid valve body 8. Solenoid valve body 12. Jumper wire
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RCPH10TLB026GAL 1
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Transmission control valve - Exploded view - Transmission control

valve
1. Nut 9. Gasket 17. Snap ring-not 25. Plug
removable
2. Seal 10. Plate 18. Ball 26. Spring spacer
3. O-ring 11. Outer modulation piston 19. Spring 27. Forward/reverse spool
4. Connector 12. Small spring 20. Control valve body 28. Flow divider piston
5. Solenoid coil 13. Medium spring 21. Bolt 29. Flow divider shaft
6. Solenoid plunger 14. Large spring 22. Hex head plug 30. Valve plate
7. Allen head bolt 15. Piston pin 23. Copper washer 31. Differential lock
solenoid valve
8. Modulation cover 16. Inner modulation piston 24. Allen head plug 32. Snap ring
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RCPH10TLB027GAL 1
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Transmission control valve - Disassemble - Four wheel drive valve

(if equipped)
1. Remove the nut.
RCPH10TLB734AAL 1
2. Remove the solenoid coil.
RCPH10TLB737AAL 2
3. Remove the solenoid valve.
RCPH10TLB738AAL 3
4. Remove the check valve from the solenoid valve

body. DO NOT try to disassemble the check valve.
There are no serviceable parts. If there is a problem,
use a new check valve.
RCPH10TLB740AAL 4
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5. Remove the three O-rings from the solenoid valve.
RCPH10TLB741AAL 5
Next operation:
Transmission control valve - Assemble (21.134)
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Transmission control valve - Assemble - Four wheel drive valve (if

equipped)
1. Install the three new O-rings on the solenoid valve.
Use clean transmission oil to lubricate the O-rings.
RCPH10TLB741AAL 1
2. Install the check valve in the valve body as shown.
RCPH10TLB740AAL 2
3. Install the solenoid valve in the solenoid valve body.

Tighten the solenoid valve to a torque of 22 Nm (195
pound-inches).
RCPH10TLB739AAL 3
4. Install the solenoid coil on the solenoid valve.
RCPH10TLB737AAL 4
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5. Install the nut.
RCPH10TLB736AAL 5
6. Tighten the nut to a torque of 8 Nm (71 pound-

inches).
RCPH10TLB735AAL 6
Next operation:
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Transmission control valve - Disassemble - Transmission control

valve
NOTE: Some of the photos in the following procedure may not be the same as the model you are repairing. The
repair procedure is the same.
1. Remove the nut for the forward/reverse solenoid.
RCPH10TLB742AAL 1
2. Remove the seal.
RCPH10TLB744AAL 2
3. Remove the first solenoid coil.
RCPH10TLB747AAL 3
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4. Remove the O-ring from the either the solenoid coil

or the solenoid plunger.
RCPH10TLB748AAL 4
5. Remove the second solenoid coil.
RCPH10TLB749AAL 5
6. Remove the O-ring from the second solenoid coil.
RCPH10TLB750AAL 6
7. The remaining O-ring can stay with either the sole-

noid coil or the solenoid plunger. Remove the re-
maining O-ring.
RCPH10TLB751AAL 7
NOTE: Step 8 to 10 are for early production N Series 2 machines, current production have a 2 wire connector per
solenoid.
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8. Remove the retainer from the rear of the connector

for the solenoid coils.
RCPH10TLB005ABL 8
NOTE: Before removing any wires from the connector, you may want to record the locations of the wires for reference
during assembly.
9. Use a small punch to release the locking tab on the
terminal.
RCPH10TLB006ABL 9
10. Pull the wire and the terminal from the connector.
RCPH10TLB007ABL 10
11. Repeat steps 8 and 10 for the remaining wires and

terminals.
12. Remove the nut for the differential lock solenoid.
RCPH10TLB752AAL 11
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13. Remove the solenoid coil.
RCPH10TLB753AAL 12
14. Loosen and remove the solenoid plunger.
RCPH10TLB754AAL 13
15. Remove the O-rings from the solenoid plunger.
RCPH10TLB755AAL 14
16. Loosen and remove the solenoid plunger with the

forward/reverse spool attached.
RCPH10TLB756AAL 15
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17. Use a small screwdriver to push down the spring as

shown so that you can disengage the notched end of
the forward/reverse spool from the post on the end of
the solenoid plunger.
RCPH10TLB011ABL 16
18. Separate the solenoid plunger (1) , the spring (2), the
spring spacer (3) , and the forward/reverse spool (4).
RCPH10TLB009ABL 17
19. Remove the O-ring from the solenoid plunger.
RCPH10TLB010ABL 18
20. Remove the four Allen head bolts that fasten the
modulation cover to the control valve body.
RCPH10TLB754AAL 19
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21. Remove the outer modulation piston (1) from the

modulation cover (2). Remove the two cover gaskets
(3) and the spacer gasket (4). Remove the check ball
(5) and spring (6) . Remove the outer modulation pis-
ton spring (7) , the inner (8) and outer spring (9) , and
the inner modulation piston pin (10) and piston (11).
RCPH10TLB758AAL 20
22. Loosen the plug at the opposite end of the bore.
RCPH10TLB759AAL 21
23. Remove the plug (1) , snap ring (2) , flow divider shaft
(3) , the spring (4) , and the flow divider piston (5)
from the bore.
RCPH10TLB764AAL 22
24. Remove the plug from the bore for the forward/re-
verse spool.
RCPH10TLB760AAL 23
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25. Remove the spring from the bore for the forward/
reverse solenoid.
RCPH10TLB761AAL 24
26. Remove the spring spacer.
RCPH10TLB762AAL 25
27. Remove the four hex head plugs (1) and the Allen
head plug (2) only if the plugs are damaged or leak-
ing. There are copper washers under the plugs.
RCPH10TLB763AAL 26
Next operation:
Transmission control valve - Inspect (21.134)
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Transmission control valve - Inspect - Transmission control valve

1. Use cleaning solvent to clean all metal parts.
2. Check the springs for wear, cracks, heat distortion,
and other damage. Replace as necessary.
3. Inspect the spool and the pistons for damage or wear.
Make sure that the orifice in the outer modulation
piston is open. Use new parts as necessary.
4. Inspect the control valve body for cracks, corrosion,
and wear. Inspect the bores for wear. Find the bore
from which the ball was removed. There is a very
small orifice in one side of this bore. Make sure that
this orifice is open. If the control valve body is bad,
you must use a new transmission control valve.
5. Find the plate that held the ball in position. Put the
ball on the hole in the plate so that the ball is in con-
tact with the edge that has the radius. Hold the plate
and the ball up to a bright light and look at the bot-
tom side of the plate and the ball. There must be no
light visible between the plate and the ball. If light is
visible, use a new plate.
Next operation:
Transmission control valve - Assemble (21.134)
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Transmission control valve - Assemble - Transmission control valve

NOTE: Some of the photos in the following procedure may not be the same as the model you are repairing. The
repair procedure is the same.
1. If the four hex head plugs (1) and the Allen head plug
(2) were removed, install the copper washers and the
plugs.
RCPH10TLB763AAL 1
2. Use clean transmission oil to lubricate the flow di-

vider shaft (1) . Install the flow divider shaft (1) . The
closed end of the flow divider piston (1) must be to-
ward the inside of the control valve body. Use clean
transmission oil to lubricate the flow divider piston (3)
. Install the spring (2) , flow divider piston (3) , and
the snap ring (4) in the bore. Install a new O-ring on
the plug (5) . Use clean transmission oil to lubricate
the O-ring on the plug (5) . Install the plug (5).
RCPH10TLB764AAL 2
3. Tighten the plug at the in the bore.
RCPH10TLB759AAL 3
4. Lubricate the new inner modulation piston (11) with

clean transmission oil. Install the new inner piston
(11) so that the end with the deeper bore is towards
the outside of the valve body. Install the spring (6)
into the small bore. Install one cover gasket (3) on
the valve body. Install the check ball (5) on top of
the spring (6) in the small bore. Install the spacer (4)
so the coined (radius) side contacts the ball. Install
the remaining cover gasket (3) onto the spacer (4) In-
stall the inner modulation piston pin (10) the inner (8)
and outer (9) spring and the outer modulation piston
spring (7) into the bore. Lubricate the outer modula-
tion piston (1) with clean transmission oil and install
the piston (1) into the modulation cover (2) with the RCPH10TLB758AAL 4
closed end towards the modulation cover.
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5. Install the modulation cover onto the valve body. In-

stall the four Allen head bolts into the cover. Tighten
the four Allen head bolts to a torque of 11 Nm (97
pound-inches).
RCPH10TLB754AAL 5
6. Install a new O-ring on the solenoid plunger. Use

clean transmission oil to lubricate the O-ring.
RCPH10TLB010ABL 6
7. Assemble the solenoid plunger (1), the spring (2), the

spring spacer (3), and the forward/reverse spool (4)
as shown above. One side of the spring spacer (3)
has a chamfer in the bore. Install the spring spacer
(3) so that the chamfer is toward the forward/reverse
spool (4).
RCPH10TLB009ABL 7
8. Use a small screwdriver to push down the spring as

shown so that you can engage the notched end of
the forward/reverse spool with the post on the end of
the solenoid plunger. When the notched end and the
post are fully engaged, release the spring to hold the
forward/reverse spool in position.
RCPH10TLB011ABL 8
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9. Install the solenoid plunger and the forward/reverse

spool in the control valve body.
RCPH10TLB757AAL 9
10. Tighten the solenoid plunger to a torque of 23 Nm

(204 pound-inches).
RCPH10TLB756AAL 10
NOTE: The following photos do not show the forward/reverse solenoid installed. The forward/reverse solenoid must
be installed before doing steps 11, 12 and 13.
11. Install the spring spacer in the bore as shown. One
side of the spring spacer has a chamfer in the bore.
Install the spring spacer so that the chamfer is toward
the inside of the control valve body. Make sure that
the end of the forward/reverse spool comes through
the hole in the spring spacer.
RCPH10TLB762AAL 11
RCPH10TLB761AAL 12
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13. Install a new O-ring on the plug. Use clean transmis-

sion oil to lubricate the O-ring. Install the plug in the
bore.
RCPH10TLB760AAL 13
14. Install new O-rings on the differential lock solenoid

plunger. Use clean transmission oil to lubricate the
O-rings.
RCPH10TLB755AAL 14
15. Install and tighten the differential lock solenoid

plunger to a torque of 15 Nm (133 pound-inches).
RCPH10TLB754AAL 15
NOTE: Step 16 to 18 are for early production N Series 2 machines, late production have a 2 wire connector per
solenoid.
16. Before inserting a terminal in the connector, use a
small screwdriver to push the locking tab out slightly
so that the locking tab will engage the plastic tab in
the connector when you insert the terminal.
RCPH10TLB008ABL 16
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17. Push each terminal into the connector until the lock-
ing tab and the plastic tab engage, locking the termi-
nal into the connector.
RCPH10TLB007ABL 17
18. After all the terminals are in the connector, install the
retainer on the rear of the connector.
RCPH10TLB005ABL 18
19. Install the differential lock solenoid coil on the sole-

noid plunger.
RCPH10TLB746AAL 19
20. Install the nut. Tighten the nut to a torque of 7 to 10

Nm (62 to 89 pound-inches).
RCPH10TLB745AAL 20
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21. Install a new O-ring on the solenoid plunger at the

control valve body. Use clean transmission oil to lu-
bricate the O-ring.
RCPH10TLB751AAL 21
22. Install a new O-ring in the solenoid coil. Use clean

transmission oil to lubricate the O-ring.
RCPH10TLB750AAL 22
23. Install the solenoid coil on the solenoid plunger.
RCPH10TLB749AAL 23
24. Install a new O-ring on the solenoid plunger. Use

clean transmission oil to lubricate the O-ring.
RCPH10TLB748AAL 24
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25. Install the remaining solenoid coil on the solenoid

plunger.
RCPH10TLB747AAL 25
26. Install the sealing washer.
RCPH10TLB744AAL 26
27. Install the nut. Tighten the nut to a torque of 7 to 10

Nm (62 to 89 pound-inches).
RCPH10TLB743AAL 27
Next operation:
Next operation:
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Index
Transmission - 21

Transmission control valve - Assemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission control valve - Assemble - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Transmission control valve - Disassemble - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission control valve - Disassemble - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transmission control valve - Exploded view - Four wheel drive valve (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission control valve - Exploded view - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transmission control valve - Inspect - Transmission control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Transmission - 21
Powershift transmission external controls - 135
580N
580SN WT
580SN
590SN
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Contents
Transmission - 21
FUNCTIONAL DATA
Powershift transmission external controls

Overview S-Type Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drawing H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drawing S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Powershift transmission external controls

Service instruction Shift Rail Position Testing - S-type Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Service instruction Shift Rail Position Physical Measurement - S-Type Transmission . . . . . . . . . . . . . . . . 7
Service instruction Hydraulic Pressure Testing Shift Rails - S-Type Transmission . . . . . . . . . . . . . . . . . . . 9
Disassemble S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assemble S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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Transmission - Powershift transmission external controls
Powershift transmission external controls - Overview S-Type

Transmission
Shift Rail Position Analog Voltages and Logical States
There is one gear position switch for each gear to monitor the position of the shift rails. The switch is open only when
the shift rail moves to that gear.
• A 5 V sensor supply voltage, ground, and the gear switches are connected to a “resistor network” that converts
the four switch states into two voltage signals.
• The 2 voltage signals should only be at distinct levels: 1V, 2V, 3V, or 4V.
• If the voltage signal is in between levels, like 3.55V for example, then look for water/contamination in the harness
especially in the 4 connectors for the gear position switches.
Gear 1 & 2 Analog Voltage Interpretation

1 Volt 1st gear switch is open, shift rail is in 1st gear position.
2 Volt Both 1st and 2nd gear switches are open, rail is between gears.
3 Volt Both 1st and 2nd gear switches are closed, rail is in neutral.
4 Volt 2nd gear switch is open, shift rail is in 2nd gear position.
Gear 3 & 4 Analog Voltage Interpretation

1 Volt 3rd gear switch is open, shift rail is in 3rd gear position.
2 Volt Both 3rd and 4th gear switches are open, rail is between gears.
3 Volt Both 3rd and 4th gear switches are closed, rail is in neutral.
4 Volt 4th gear switch is open, shift rail is in 4th gear position.
The TRAX controller interprets these analog voltages and creates a logical status for each of the 4 gear position
switches. The gear which is engaged is shown as “OFF”. The TRAX controller always makes sure the transmission
is shifted into neutral upon startup. After this initial check for neutral, the transmission will shift into which ever gear
is requested by the FNR lever position. The following table shows the gear switch logical status for each gear:
Gear Gear switch 1 logic Gear switch 2 logic Gear switch 3 logic Gear switch 4 logic
Neutral ON ON ON ON
1st OFF ON ON ON
2nd ON OFF ON ON
3rd ON ON OFF ON
4th ON ON ON OFF
Gear command 1 and 2 truth table

The selection of 1st through 4th gears with the FNR lever is commanded by 2 on/off inputs into the TRAX controller.
Note that Gear Command 2 is also controlled by the Comfort Steer Cutout Relay and fuse (See machine electrical
schematic). The TRAX controller interprets these two signals as follows:
Gear Command 1 (Trax pin 9) Command 2 (Trax pin 47)

1st 12 Volts 0 Volts
2nd 0 Volts 0 Volts
3rd 0 Volts 12 Volts
4th 12 Volts 12 Volts
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Transmission control valve - Drawing H-Type
RCPH11TLB012FAL 1
Control Valve
(1) Pulse Width Modulation 2/4 solenoid, port (5) 4WD solenoid, port E
A
(2) Reverse solenoid, port B (6) 2nd/4th solenoid, port F
(3) Forward solenoid, port C (7) Differential lock solenoid, port G
(4) Pulse Width Modulation 1/3 solenoid, port (8) 1st/3rd solenoid, port H
D
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Transmission control valve - Drawing S-Type

The transmission control valve, mounted on top of the transmission, contains the 8 actuating solenoids which control
the routing of the oil to shift the transmission.
RCPH11TLB016GAL 1
Solenoid Operation when energized

(1) HDL Engage the differential lock in the rear axle.
(2) 4WD Release the SAHR 4WD clutch for 2WD operation.
(3) REV PWM solenoid to ramp up pressure and engage the reverse clutch.
(4) FWD PWM solenoid to ramp up pressure and engage the forward clutch.
(5) S2 Engages 2nd gear by dumping pressure to the 1N2 piston.
(6) S4 Engages 4th gear by dumping pressure to the 3N4 piston.
(7) S3 Engages 3rd gear by sending pressure to the 3rd piston and dumping the 4th piston.
(8) S1 Engages 1st gear by sending pressure to the 1st piston and dumping the 2nd piston.
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Powershift transmission external controls - Service instruction

Shift Rail Position Testing - S-type Transmission
To test the resistor network and the gear position switches
follow the procedure below. The tests can be done with the
engine off and the key on.
1. Remove all four 2-pin connectors that go to the gear
position switches.
2. Carefully Insert a jumper (piece of wire) into each
connector, shorting the pins together to simulate the
gear switches being closed.
3. With the EST monitor the fields in the slide above.
4. Remove one jumper at a time. If the 1stgear position
switch jumper is removed then the “gear 1 and 2 ana-
log voltage” and “gear switch 1 logical status” should
match the expected values below, 1V and OFF.
5. The actual gear position switches can also be
checked. If the unit is off, the shift rails should be in
neutral and all the switches will be closed. If one of
the switches is measured as open, either the switch
is faulty or the shift rail is not in neutral.
6. The individual switches can be removed and manu-
ally cycled by pressing the plunger while monitoring
with the EST. Depressing the switch plunger should
cause the switch to go open, with an ‘OFF’ indication
on the EST.
Following is a diagram of the switch locations as facing the
right side of the transmission:
RCPH11TLB081AAL 1
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Shift Rail Position Physical Measurement - S-Type Transmission
If the previous electrical tests show that the problem is not
electrical, then the shift rails can be physically checked for
proper position. Remove the two plugs from the rear trans-
mission housing adjacent to the shift rails.
RCPH11TLB001GAL 1
(1) 3rd and 4th shift rail plug

. (2) 1st and 2nd shift rail plug
Measure the depth of the end of the rail in relation to the
edge of the transmission housing at the plug which was
removed.
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RCPH11TLB011FAL 2
(1) Measure the rail depth here
Measurement Interpretation
18 mm (0.71 in) Rail is in 1st gear or 3rd gear
29 mm (1.14 in) Neutral rail position
40 mm (1.57 in) Rail is in 2nd gear or 4th gear position
If the rail is out of position, then transmission hydraulic

pressure tests should be performed to determine whether
the correct hydraulic pressures are being sent to the shift
rail positioning pistons to center the shift rails into neu-
tral. The pressures to be checked should be determined
by which shift rail is out of position.
If the pressure tests show correct, then the shift rail is phys-
ically jammed in position.
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Hydraulic Pressure Testing Shift Rails - S-Type Transmission
A pressure gauge can be installed at the check ports to
monitor pressure applied to the shifting pistons. All port
locations are 9/16-18 UNF ORB.
RCPH11TLB012GAL 1
Right Side View
(18) 1st gear switch (24) 2nd test port

(19) 3rd gear switch (25) Return oil from service brake
(20) 2nd gear switch (26) 3N4 test port
(21) 4th gear switch (27) 3rd test port
(22) SAHR 4WD test port (28) 1N2 test port
(23) 4th test port (29) 1st test port
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Gear 1N2 1st 2nd 3N4 3rd 4th

Neutral 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar
(188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5
psi) psi) psi) psi)
1st 13 - 17 bar 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar
(188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5
psi) psi) psi) psi)
2nd 0 bar (0.0 psi) 0 bar (0.0 psi) 13 - 17 bar 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar
(188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5
psi) psi) psi)
3rd 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar 13 - 17 bar 13 - 17 bar 0 bar (0.0 psi)
(188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5
psi) psi) psi) psi)
4th 13 - 17 bar 0 bar (0.0 psi) 13 - 17 bar 0 bar (0.0 psi) 0 bar (0.0 psi) 13 - 17 bar
(188.5 - 246.5 (188.5 - 246.5 (188.5 - 246.5
psi) psi) psi)
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Transmission control valve - Disassemble S-Type (SPS Power

1. Disconnect all electrical wires and drain the transmis-
sion.
2. Remove the screws (1) and remove the control valve
(2).
RCPH10TLB152ACL 1
3. Remove the gasket (1).
RCPH10TLB153ACL 2
4. Remove the screws (1) and the HDL and 4WD valves
(2).
RCPH10TLB154ACL 3
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HDL and FWD valves positions:
RCPH10TLB155ACL 4
HDL and FWD valves dimensions:
RCPH10TLB040ACL 5
5. Remove the O-rings as needed.
RCPH10TLB158ACL 6
6. Remove the screws and the REV and FWD valves.
RCPH10TLB154ACL 7
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REV and FWD valves positions:
RCPH10TLB156ACL 8
REV and FWD valves dimensions:
RCPH10TLB041ACL 9
7. Remove the O-rings (1) as needed.
RCPH10TLB159ACL 10
8. Remove the S2 and S4 solenoid valves.

S2 and S4 solenoid valves positions:
RCPH10TLB160ACL 11
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S2 and S4 solenoid valves dimensions:
RCPH10TLB042ACL 12
9. Unscrew the nut.
RCPH10TLB192ACL 13
10. Remove the nut.
RCPH10TLB191ACL 14
11. Remove the solenoid.
RCPH10TLB190ACL 15
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RCPH10TLB190ACL 16
RCPH10TLB189ACL 17
14. Unscrew the solenoid tube.
RCPH10TLB188ACL 18
15. Remove the solenoid tube. Remove the O-rings as

needed.
RCPH10TLB187ACL 19
16. Remove the S1 (1st and 2nd gear) and S3 (3rd and
4th gear) solenoid valves.
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S1 and S3 solenoid valves positions:
RCPH10TLB252ACL 20
S1 and S3 solenoid valves dimensions:
RCPH10TLB043ACL 21
17. Unscrew the nut.
RCPH10TLB186ACL 22
18. Remove the nut.
RCPH10TLB185ACL 23
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RCPH10TLB184ACL 24
20. Unscrew the solenoid tube.
RCPH10TLB183ACL 25
21. Remove the solenoid tube. Remove the O-rings as

needed.
RCPH10TLB182ACL 26
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22. Remove the screws, circuit plate, and O-Rings. (1).
RCPH10TLB080ACL 27
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Transmission control valve - Assemble S-Type (SPS Power

NOTE: Some of the following images may not represent your transmission, the procedures are the same.
1. Lubricate and install the O-rings, oil circuit plate, and
screws. .
RCPH10TLB080ACL 1
2. Lubricate and install the O-rings on the solenoid tube

for the S1 and S3 solenoid valves.
3. Install the solenoid tube.
RCPH10TLB182ACL 2
4. Tighten the solenoid tube to specifications.
RCPH10TLB183ACL 3
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5. Install the solenoid.
RCPH10TLB184ACL 4
6. Install the nut.
RCPH10TLB185ACL 5
7. Tighten the nut to specifications. Powershift trans-

mission - Torque (21.113)
RCPH10TLB180ACL 6
8. Lubricate and install the O-rings for the S2 and S4

solenoid valves.
9. Install the solenoid tube.
RCPH10TLB187ACL 7
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10. Tighten the solenoid tube to specifications.
RCPH10TLB181ACL 8
RCPH10TLB189ACL 9
RCPH10TLB189ACL 10
RCPH10TLB190ACL 11
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14. Install the nut.
RCPH10TLB191ACL 12
15. Tighten the nut to specifications Powershift trans-

mission - Torque (21.113).
RCPH10TLB179ACL 13
16. Lubricate and install the O-rings for the REV and
FWD valves.
17. Install the valves.
RCPH10TLB159ACL 14
18. Lubricate and install the O-rings for the HDL and
4WD valves.
19. Install the valves.
RCPH10TLB158ACL 15
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20. Install the screws for the HDL, 4WD, REV and FWD
valves. Tighten the screws to specifications.
RCPH10TLB253ACL 16
21. Lubricate and install the gasket (1).
RCPH10TLB153ACL 17
22. Install the control valve (1) and the screws (2).
Tighten the screws to specifications. Powershift
transmission - Torque (21.113)
RCPH10TLB152ACL 18
23. Disconnect all electrical wires and drain the transmis-

sion.
Next operation:
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Index
Transmission - 21

Powershift transmission external controls - Overview S-Type Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powershift transmission external controls - Service instruction Hydraulic Pressure Testing Shift Rails - S-Type Trans-
mission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Powershift transmission external controls - Service instruction Shift Rail Position Physical Measurement - S-Type
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Powershift transmission external controls - Service instruction Shift Rail Position Testing - S-type Transmission 6
Transmission control valve - Assemble S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . . . . 19
Transmission control valve - Disassemble S-Type (SPS Power Synchro) - Hydraulic control valve . . . . . . . . . . . 11
Transmission control valve - Drawing S-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Transmission control valve - Drawing H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Transmission - 21
Power Shuttle transmission internal components - 154
580N
580SN WT
580SN
590SN
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Contents
Transmission - 21
FUNCTIONAL DATA
Transmission drive and driven shafts

Exploded view - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view - Shift rod and forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exploded view - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE
Transmission drive and driven shafts

Disassemble - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspect - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Inspect - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Assemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Adjust - Backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Disassemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Inspect - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Assemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Disassemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Inspect - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Assemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Disassemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Inspect - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Assemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Disassemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Inspect - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Assemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
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Transmission - Power Shuttle transmission internal components
Transmission drive and driven shafts - Exploded view - Input shaft

Input shaft
1. Seal ring 11. Clutch plate (12) 21. Rivet
2. Snap ring 12. Lock ring 22. Gear
3. Bearing 13. Lock-spring cover 23. Bearing
4. Spacer 14. Spring 24. Snap ring
5. Needle bearing 15. Clutch sleeve 25. Seal rings
6. Gear 16. Clutch piston 26. Snap ring
7. Thrust washer 17. Seal ring 27. Bearing
8. Lock ring 18. Seal ring 28. Pump drive shaft
9. Clutch plate lock ring 19. Inner shaft 29. Seal ring
10. Clutch drive plate (14) 20. Split pin
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RCPH10TLB022GAL 1
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Transmission drive and driven shafts - Exploded view - Shift rod

and forks
Shift rod and forks
1. Boot 7. O-ring 13. Detent ball 19. Shift rod for third and
fourth gear
2. Band 8. Spring 14. Detent plug 20. Shift rod for first and
second gear
3. Shift lever 9. Bushing 15. Washer 21. Roll pin
4. Pin 10. Snap ring 16. Detent spring 22. Shift fork for third and
fourth gear
5. Allen head screw 11. Shift collar 17. Bolt 23. Shift fork for first and
second gear
6. Shifter housing 12. Plate 18. Copper washer
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RCPH10TLB024GAL 1
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Transmission drive and driven shafts - Exploded view - Secondary

shaft
Secondary shaft
1. Bearing 8. Steel ring 15. Sleeve 22. Thrust washer
2. Lock ring 9. Coated ring 16. Gear 23. Bearing
3. Shim 10. Tapered friction ring 17. Split pin 24. Seal
4. Thrust washer 11. Hub 18. Secondary shaft 25. Flange
5. Gear 12. Spring 19. Gear 26. Washer
6. Spacer 13. Ball 20. Clutch ring 27. O-ring
7. Synchronizer ring 14. Lock spring plate 21. Synchronizer ring 28. Bolt
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RCPH10TLB023GAL 1
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Transmission drive and driven shafts - Exploded view - Four wheel

drive shaft
Four wheel drive shaft
1. Bolt 7. Bearing 13. Sleeve
2. Washer 8. Teflon sealing ring 14. Pipe plug
3. O-ring 9. Special washer 15. Shaft
4. Four-wheel drive flange 10. Snap ring 16. Four wheel drive clutch gear
5. Cover 11. Spacer
6. Seal 12. Spring
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RCPH10TLB025GAL 1
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Transmission drive and driven shafts - Disassemble - Input shaft

NOTE: Do steps 1 and 2 before you disassemble the input shaft. This will help to locate any problems. After you
assemble the input shaft, the tests will be done again to make sure that the input shaft is working correctly.
1. Apply compressed air of approximately 620 kPa (90
psi) to the forward clutch passage. Listen to hear
the forward piston moving to lock the forward clutch
pack. Try to move the forward gear. The forward
gear must not turn on the input shaft. Try to move the
reverse gear. The reverse gear must turn freely on
the input shaft. If the clutches do not work correctly,
inspect the parts closely during disassembly so that
you can find and correct the problem.
psi) to the reverse clutch passage. Listen to hear
the reverse piston moving to lock the reverse clutch
pack. Try to move the reverse gear. The reverse
forward gear. The forward gear must turn freely on
inspect the parts closely during disassembly so that
you can find and correct the problem.
3. Use the bottom piece of CAS-2379 special tool as
shown to fasten the input shaft in the vise so that the
reverse clutch is up.
RCPH10TLB786AAL 1
4. Remove the sealing ring.
RCPH10TLB788AAL 2
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5. Remove the snap ring above the bearing.
RCPH10TLB787AAL 3
6. Install a bearing separator under the gear as shown.

DO NOT install the bearing separator between the
gear and the bearing. Install a puller on the bearing
separator. Use a shaft protector between the puller
and the end of the input shaft. Use molydisulfide
grease to lubricate the shaft protector and the end
of the puller. Make sure that you pull only until the
bearing is free. Pulling any farther can damage the
parts.
RCPH10TLB789AAL 4
RCPH10TLB790AAL 5
RCPH10TLB791AAL 6
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9. Remove the gear.
RCPH10TLB792AAL 7
RCPH10TLB793AAL 8
RCPH10TLB794AAL 9
RCPH10TLB795AAL 10
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13. Tap lightly on the thrust plate to move the thrust plate
down so that there is clearance between the snap
ring and the thrust plate.
RCPH10TLB796AAL 11
14. Tap lightly on the thrust plate to move the thrust plate
ring and the thrust plate. Remove the snap ring.
RCPH10TLB797AAL 12
15. Install the top piece of the CAS-2379 special tool as

shown. Use the three threaded rods and nuts to fas-
ten the two pieces together.
RCPH10TLB798AAL 13
16. Tighten the nuts evenly to compress the spring.

Compress the spring just enough to get access to
the snap ring.
RCPH10TLB800AAL 14
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RCPH10TLB799AAL 15
CAS-2379 special tool.
RCPH10TLB800AAL 16
19. Use pry bars to lift the thrust plate evenly.
RCPH10TLB922AAL 17
20. Lift the thrust plate and the steel discs and the friction
discs out of the housing as a complete unit. Set the
complete unit on top of the body.
RCPH10TLB809AAL 18
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21. Place a mark below the groove on the housing.
RCPH10TLB878AAL 19
22. Place a mark on each steel and friction disc and the
thrust plate. These marks will be used for reference
during the reassembly procedure.
RCPH10TLB879AAL 20
23. Place a mark on top of the thrust plate and each steel
and friction disc as they are removed. These marks
will be used for reference during the reassembly pro-
cedure.
RCPH10TLB880AAL 21
RCPH10TLB881AAL 22
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RCPH10TLB807AAL 23
protection.
26. Use compressed air in the port shown to remove the
piston.
RCPH10TLB801AAL 24
27. Remove the piston.
RCPH10TLB802AAL 25
28. Put the input shaft in the bottom piece of the CAS-
2379 special tool as shown so that the forward clutch
is up.
RCPH10TLB923AAL 26
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21.154 / 18
29. Remove the four sealing rings (1)
RCPH10TLB819AAL 27
RCPH10TLB924AAL 28

gear and the bearing. Install an acceptable puller on
the bearing separator. Use a shaft protector between
the puller and the end of the input shaft. Use moly-
disulfide grease to lubricate the shaft protector and
the end of the puller. Make sure that you pull only
until the bearing is free. Pulling any farther can dam-
age the parts.
RCPH10TLB925AAL 29
RCPH10TLB926AAL 30
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21.154 / 19
RCPH10TLB927AAL 31
NOTE: It is possible that the gear moved partially out of the clutch pack when the bearing was removed. If this occurs,
it can be difficult to remove the roll pin. Move the gear as necessary to remove the roll pin.
RCPH10TLB928AAL 32
RCPH10TLB929AAL 33
RCPH10TLB930AAL 34
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37. Tap lightly on the end plate to move the end plate
ring and the end plate.
RCPH10TLB932AAL 35
RCPH10TLB931AAL 36
39. Use pry bars to lift the end plate evenly. Remove the
end plate.
RCPH10TLB933AAL 37
RCPH10TLB934AAL 38
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41. Install the top piece of the CAS-2379 special tool as

shown. Use the three threaded rods and nuts to fas-
ten the two pieces together.
RCPH10TLB935AAL 39
42. Tighten the nuts evenly to compress the spring.

Compress the spring just enough to get access to
the snap ring.
RCPH10TLB936AAL 40
RCPH10TLB937AAL 41
CAS-2379 special tool.
RCPH10TLB938AAL 42
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45. Remove the retainer plate.
RCPH10TLB939AAL 43
RCPH10TLB940AAL 44
47. Lift the thrust plate and the steel discs and the friction
discs out of the housing as a complete unit. Set the
complete unit on top of the body.
RCPH10TLB941AAL 45
48. Follow the same procedure as Step 21and Step 22for

marking the top of the thrust plate and the steel and
friction discs as they are removed from the housing.
RCPH10TLB806AAL 46
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21.154 / 23
protection.
50. Use compressed air in the port shown to remove the
piston.
RCPH10TLB803AAL 47
51. Remove the piston.
RCPH10TLB802AAL 48
52. Remove the sealing ring from the OD and the ID of

each piston.
RCPH10TLB805AAL 49
Next operation:
Transmission drive and driven shafts - Inspect (21.154)
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Transmission drive and driven shafts - Inspect - Input shaft

1. Check the springs for broken or cracked coils. Com-
pare the heights of the two springs. If the two springs
are not approximately the same height, use new
springs. The correct spring height is approximately
85.5 mm (3.4 inches). Use new parts as required.
2. Check the sealing ring grooves (large and small) for
wear and damage. Use new parts as required.
3. Check the teeth on the gears for wear and damage.
If a tooth is badly damaged, be sure to inspect the
gear or spline that is in mesh with the damaged gear.
Use new parts as required.
4. Check the splines on the output shaft for wear and
damage. Check the passages in the output shaft
to be sure that the passages are open and free of
foreign material. Use new parts as required.
5. Check the ball bearings and the needle bearings for
flat areas, pitting, and other damage. Use new parts
as required.
6. If the clutch discs are to be used again, keep the
clutch packs separate and record which clutch pack
goes with each clutch. Use new parts as required.
RCPH10TLB804AAL 1
RCPH10TLB942AAL 2
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7. Use a straight edge to check each steel disc (1) and

each friction disc (2) to be sure each part is flat. If
a steel disc (1) or a friction disc (2) is not flat, a new
part must be installed during assembly. If the friction
discs (2) are smooth or almost smooth, use new par
ts during assembly. If the friction material is damaged
or appears burned, use new parts during assembly.
Also, check the splines for wear. Inspect the steel
discs (1) for pitting, scoring, or other damage. If there
is any damage, use new parts during assembly. If
you will be using new friction discs, soak the friction
discs in clean transmission oi l for at least an hour
before assembly. If you are using the old friction
discs, make sure that the friction surfaces are coated RCPH10TLB943AAL 3
with transmission oil before assembly.

8. Inspect the bore and the shaft in the input shaft hous-
ing for damage that will cause leakage when the
clutch is assembled. Check the slots in the side of
the input shaft housing for damage from the tangs
on the steel discs. Use new par ts as required during
assembly.
9. Inspect the end of the clutch pack housing line bore
holes, if a rivet is coming out of the housing (arrow),
replace the rivet.
RCPH10TLB818AAL 4
Next operation:
Transmission drive and driven shafts - Assemble (21.154)
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Transmission drive and driven shafts - Assemble

1. Use clean transmission oil to lubricate the sealing
rings. Install new sealing rings in each piston.
RCPH10TLB805AAL 1
2. Slide the 380001926 piston installation tool on the

input shaft.
RCPH10TLB820AAL 2
3. Use clean transmission oil to lubricate the edge and

the bore of the piston. Install the piston. Remove
the 380001926 piston installation tool from the input
shaft.
the bore of the piston. Install the piston.
RCPH10TLB806AAL 3
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21.154 / 27
RCPH10TLB940AAL 4
6. Install the retainer plate. The side that has a raised

area around the bore goes down.
RCPH10TLB939AAL 5
7. Install the top piece of the CAS-2379 special tool.

Use the three threaded rods and nuts to fasten the
two pieces together. Tighten the nuts evenly to com-
press the spring just enough to get access to the
snap ring groove in the input shaft. Install the snap
ring. Loosen the nuts to relieve the spring tension
and remove the CAS-2379 special tool. Make sure
that the outer edge of the snap ring is seated in the
groove in the retainer plate.
RCPH10TLB961AAL 6
8. Install the pin.
RCPH10TLB962AAL 7
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9. Use clean transmission oil to lubricate the thrust

washer. Install 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 up.
RCPH10TLB963AAL 8
10. Use clean transmission oil to lubricate the needle

bearings. Install the needle bearing.
RCPH10TLB964AAL 9
11. To assemble the clutch pack, start with the gear on

the bench. Install the thrust plate so that the refer-
ence mark on top of the plate made during disas-
sembly is facing towards the gear.
RCPH10TLB971AAL 10
12. Install one steel disc with reference mark on top of

the steel disc towards the gear followed by one fric-
tion disc with the reference mark on top towards the
gear.
RCPH10TLB972AAL 11
NOTE: If you will be using new friction discs, soak the friction discs in clean transmission oil for at least an hour before
assembly. If you are using the old friction discs, make sure that the friction surfaces are coated with transmission oil
before assembly.
47365539 08/07/2012
21.154 / 29

the steel disc towards the gear.
RCPH10TLB048ABL 12
14. Repeat steps 12 and 13 until all the clutch discs are
installed. The assembled clutch pack must contain
seven steel discs and six friction discs.
15. Make sure that the tabs with reference marks on all
the steel discs are aligned with each other. Hold the
clutch pack together so that the parts do not move
and rotate the clutch pack so that the clutch discs
are down. Put the clutch pack on the clutch housing
as shown so that the tabs with the reference marks
on the steel discs are almost ready to start into the
slot in the clutch housing with the reference mark.
RCPH10TLB965AAL 13
16. Use two screwdrivers in opposite slots in the clutch

housing to support the clutch pack as you start the
clutch pack into the clutch housing. Move the clutch
pack down slowly and evenly, making sure that all
the tabs are going into the slots. Make sure all of
the tabs with reference marks are aligned in the slot
in the housing with the reference mark. Also make
sure that the gear moves down with the clutch pack.
RCPH10TLB966AAL 14
17. When all the clutch discs are down, and the gear is
down as far as the thrust plate will permit, remove the
screwdrivers. Use a punch and a hammer to move
the thrust plate down evenly just far enough to get
access to the snap ring groove in the clutch housing.
RCPH10TLB967AAL 15
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RCPH10TLB968AAL 16
19. Use two screwdrivers to move the thrust plate up until

the thrust plate is against the snap ring. There is a
recess in the outer edge of the thrust plate. When
the thrust plate is up all the way, the inner edge of
the snap ring will fit in this recess.
RCPH10TLB969AAL 17

side with the oil grooves is down.
RCPH10TLB927AAL 18
21. Use an acceptable driver to drive the bearing onto

the input shaft until the bearing makes contact with
the thrust washer.
RCPH10TLB970AAL 19
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21.154 / 31
RCPH10TLB924AAL 20
NOTE: For clarity of the Teflon sealing ring installation procedure the following photos do not show the clutch pack,
gear, spacer, bearing, and snap ring installed on the input shaft. Steps 1 through 22 must be performed before in-
stalling the Teflon sealing ring on the input shaft.
pander/protector.
RCPH10TLB821AAL 21

spacer onto the shaft. Heat the Teflon sealing ring
to 80° to 100° C (176° to 212° F). Install the Teflon
sealing ring onto the expander/protector.
RCPH10TLB831AAL 22

groove in the shaft. Remove the pusher, protector,
RCPH10TLB838AAL 23
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21.154 / 32

RCPH10TLB839AAL 24
from the shaft.
RCPH10TLB840AAL 25

pander/protector.
RCPH10TLB822AAL 26

RCPH10TLB832AAL 27
47365539 08/07/2012
21.154 / 33

RCPH10TLB837AAL 28

RCPH10TLB839AAL 29
from the shaft.
RCPH10TLB840AAL 30

pander/protector.
RCPH10TLB823AAL 31
47365539 08/07/2012
21.154 / 34

RCPH10TLB833AAL 32

RCPH10TLB836AAL 33

RCPH10TLB839AAL 34
from the shaft.
RCPH10TLB840AAL 35
47365539 08/07/2012
21.154 / 35

pander/protector.
RCPH10TLB824AAL 36

RCPH10TLB834AAL 37

RCPH10TLB835AAL 38

RCPH10TLB839AAL 39
47365539 08/07/2012
21.154 / 36
from the shaft.
RCPH10TLB840AAL 40
43. Put the input shaft in the bottom piece of the

CAS2379 special tool so that the reverse clutch
housing is up. Slide the 380001926 piston installa-
tion tool on the input shaft.
RCPH10TLB825AAL 41

the bore of the piston. Install the piston. Remove the
piston installation tool.
45. Install the sleeve.
RCPH10TLB882AAL 42
46. Install the pressure plate and the spring. The raised
area around the bore of the pressure plate must go
down. The side that has the groove around the bore
should face up. The outer edge of the snap ring must
fit in the groove after the parts are assembled.
RCPH10TLB881AAL 43
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21.154 / 37
47. Install the top piece of the CAS-2379 special tool.

Use the three threaded rods and nuts to fasten the
two pieces together. Tighten the nuts evenly to com-
press the spring just enough to get access to the
snap ring groove in the input shaft. Install the snap
ring. Loosen the nuts to relieve the spring tension
and remove the CAS-2379 special tool. Make sure
that the outer edge of the snap ring is seated in the
groove in the retainer plate.
RCPH10TLB973AAL 44
48. Install the pin.
RCPH10TLB974AAL 45

side with the oil grooves is up.
RCPH10TLB975AAL 46
50. Use clean transmission oil to lubricate the needle

bearing. Install the needle bearing.
RCPH10TLB793AAL 47
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21.154 / 38
51. To assemble the clutch pack, start with the gear on

the bench. Install the thrust plate so that the refer-
ence mark on top of the plate made during disas-
sembly is facing towards the gear.
RCPH10TLB971AAL 48
NOTE: If you will be using new friction discs, soak the friction discs in clean transmission oil for at least an hour before
assembly. If you are using the old friction discs, make sure that the friction surfaces are coated with transmission oil
before assembly.
the steel disc towards the gear followed by one fric-
tion disc with the reference mark on top towards the
gear.
RCPH10TLB972AAL 49

the steel disc towards the gear.
RCPH10TLB048ABL 50
54. Repeat steps 52 and 53until all the clutch discs are
installed. The assembled clutch pack must contain
seven steel discs and six friction discs.
47365539 08/07/2012
21.154 / 39
55. Make sure that the tabs with reference marks on all
the steel discs are aligned with each other. Hold the
clutch pack together so that the parts do not move
and rotate the clutch pack so that the clutch discs
are down. Put the clutch pack on the clutch housing
as shown so that the tabs with the reference marks
on the steel discs are almost ready to start into the
slot in the clutch housing with the reference mark.
RCPH10TLB976AAL 51
56. Use two screwdrivers in opposite slots in the clutch

housing to support the clutch pack as you start the
clutch pack into the clutch housing. Move the clutch
pack down slowly and evenly, making sure that all
the tabs are going into the slots. Make sure all of
the tabs with reference marks are aligned in the slot
in the housing with the reference mark. Also make
sure that the gear moves down with the clutch pack.
RCPH10TLB977AAL 52
57. When all the clutch discs are down, and the gear is
down as far as the thrust plate will permit, remove the
screwdrivers. Use a punch and a hammer to move
the thrust plate down evenly just far enough to get
access to the snap ring groove in the clutch housing.
RCPH10TLB978AAL 53
RCPH10TLB979AAL 54
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59. Use two screwdrivers to move the thrust plate up until

the thrust plate is against the snap ring. There is a
recess in the outer edge of the thrust plate. When
the thrust plate is up all the way, the inner edge of
the snap ring will fit in this recess.
RCPH10TLB980AAL 55
60. Use clean transmission oil to lubricate the spacer (1)

and install the spacer (1) on the input shaft. Install the
bearing (2) onto the input shaft. Use an acceptable
driver (3) to drive the bearing onto the input shaft until
the bearing (2) makes contact with the spacer (1)
RCPH10TLB981AAL 56
RCPH10TLB919AAL 57
gear, spacer, bearing, and snap ring installed on the input shaft. Steps 43 through 61 must be performed before
installing the Teflon sealing ring on the input shaft.
pander/protector.
RCPH10TLB826AAL 58
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63. Slide the expander/protector and spacer onto the in-

put shaft. Heat the Teflon sealing ring to 80° to 100°
C (176° to 212° F). Install the Teflon sealing ring onto
the 380001428 expander/protector.
RCPH10TLB829AAL 59

RCPH10TLB830AAL 60

RCPH10TLB841AAL 61
from the shaft.
RCPH10TLB827AAL 62
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67. Measure the clutch disc clearance for each clutch

assembly. The end cover must be all the way up
against the snap ring. Use a feeler gauge to mea-
sure the distance between the end cover and the first
metal disc. The distance must be 2.3 to 4.3 mm (0.09
to 0.17 inch). If the distance is not within specifica-
tion, the clutch is probably assembled wrong. Clutch
plate wear will not cause the distance to be outside
the specification.
RCPH10TLB982AAL 63
NOTE: The art shows a clutch pack without the PTO through shaft, the procedures for steps 68 and 69 are the same.
psi) to the forward clutch passage. Listen to hear
the forward piston moving to lock the forward clutch
pack. Try to move the forward gear. The forward
reverse gear. The reverse gear must turn freely on
the input shaft . If the clutches do not work correctly,
disassemble the clutches to find the problem.
RCPH10TLB054GAL 64
Clutch pack
1. Forward clutch passage 4. Forward clutch pack 7. Input shaft
2. Reverse clutch passage 5. Reverse clutch pack
3. Forward gear 6. Reverse gear

psi) to the reverse clutch passage. Listen to hear
the reverse piston moving to lock the reverse clutch
pack. Try to move the reverse gear. The reverse
forward gear. The forward gear must turn freely on
disassemble the clutches to find the problem.
Next operation:
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Transmission drive and driven shafts - Disassemble - Secondary

shaft
1. Support the secondary shaft on blocks on the bench
as shown.
RCPH10TLB765AAL 1

gear and the bearing. If the bearing separator has a
beveled edge, the beveled edge must be down. Do
not tighten the bearing separator so much that the
bearing separator pushes the synchronizer down. In-
stall an acceptable puller on the bearing separator.
Use a shaft protector between the puller and the end
of the secondary shaft. Use molydisulfide grease to
lubricate the shaft protector and the end of the puller.
Make sure that you pull only until the bearing is free.
Pulling any farther can damage the parts .
RCPH10TLB766AAL 2
RCPH10TLB767AAL 3
RCPH10TLB768AAL 4
47365539 08/07/2012
21.154 / 44
5. Remove the third gear from the shaft.
RCPH10TLB769AAL 5
6. Remove the synchronizer assembly.
RCPH10TLB770AAL 6
7. Use a feeler gauge to measure the clearance be-

tween the clutch ring (1)and the edge of the tapered
friction ring (2). This clearance (3) should be approx-
imately 1.0 mm (0.04 inch) with used parts in good
condition. If the clearance is 0.5 mm (0.02 inch) or
less, use new parts as required. Repeat the mea-
surement for the opposite side of the synchronizer
assembly before disassembly.
RCPH10TLB810AAL 7
8. Remove the clutch ring from each side of the syn-

chronizer assembly.
RCPH10TLB817AAL 8
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21.154 / 45
9. Remove the tapered friction ring from each side of

the synchronizer assembly.
RCPH10TLB816AAL 9
10. Inspect the clutch ring teeth for wear, wear in excess
of 0.5 mm (0.02 inch) the ring must be replaced.
RCPH10TLB815AAL 10
NOTE: The parts may fly out of the hub when you do the following step. Putting the synchronizer assembly in a
cardboard box during this step can prevent loss of parts.
11. Remove the sleeve from the synchronizer hub.
When the sleeve is removed from the synchronizer
hub the spring plates, hub pins and hub springs will
be released from the synchronizer hub. Be careful
not to lose any of these parts.
RCPH10TLB893AAL 11
12. This photo shows the relationship of the balls (1) , the
spring plates (2) , the springs (3) , and the hub (4)
RCPH10TLB949AAL 12
47365539 08/07/2012
21.154 / 46
13. Remove fourth gear.
RCPH10TLB771AAL 13
14. Turn the secondary shaft over so that second gear is

at the top. You can use a vise with soft jaws to hold
the secondary shaft in position.
RCPH10TLB772AAL 14
15. Install a bearing separator under the bearing race as

shown. If the bearing separator has a beveled edge,
the beveled edge must be down. Do not tighten the
bearing separator so much that the bearing separa-
tor pushes the synchronizer down. Install an accept-
able puller on the bearing separator. Use a shaft
protector between the puller and the end of the sec-
ondary shaft . Use molydisulfide grease to lubricate
the shaft protector and the end of the puller. Make
sure that you pull only until the bearing race is free.
Pulling any farther can damage the parts.
RCPH10TLB773AAL 15
16. Remove the bearing race from the shaft.
RCPH10TLB774AAL 16
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21.154 / 47
17. Remove the snap ring from the shaft.
RCPH10TLB775AAL 17
18. Remove the shim(s) and the thrust washer.
RCPH10TLB776AAL 18
19. Remove the pin.
RCPH10TLB777AAL 19
20. Remove second gear.
RCPH10TLB778AAL 20
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RCPH10TLB779AAL 21
22. Remove the synchronizer ring and the first-second

synchronizer as an assembly.
RCPH10TLB780AAL 22

tween the bottom of the teeth on the synchronizer
ring and the edge of the sleeve on the outside of
the synchronizer assembly. This clearance should
be approximately 1.0 mm (0.04 inch) with used parts
in good condition. If the clearance is 0.5 mm (0.02
inch) or less, use new parts as required. Repeat the
measurement for the opposite side of the synchro-
nizer assembly before disassembly.
24. Remove the steel ring (1) and the bronze ring (2)to-
gether.
RCPH10TLB946AAL 23
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21.154 / 49
25. Remove the tapered friction ring.
RCPH10TLB947AAL 24
26. Turn the synchronizer assembly over and remove the

synchronizer ring from the other side.
RCPH10TLB945AAL 25
27. Remove the steel ring (1) and the bronze ring (2)to-
gether.
RCPH10TLB946AAL 26
28. Remove the tapered friction ring.
RCPH10TLB947AAL 27
NOTE: The parts will fly out of the hub when you do the following step. Putting the synchronizer assembly in a
cardboard box during this step can prevent loss of parts.
47365539 08/07/2012
21.154 / 50
29. Support the sleeve on blocks. Push down on the hub

while you use a punch to push the detent assemblies
out of the sleeve and hub. Remove the sleeve from
the hub.
RCPH10TLB948AAL 28
30. This photo shows the relationship of the balls (1), the
spring plates (2), the springs (3), and the hub (4).
RCPH10TLB949AAL 29
31. Remove first gear.
RCPH10TLB781AAL 30
32. If equipped with four wheel drive, remove the snap

ring from the four wheel drive gear.
RCPH10TLB782AAL 31
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33. Remove the four wheel drive gear, if equipped. On

two-wheel drive transmissions, there is a raised area
on the shaft.
RCPH10TLB783AAL 32
34. If equipped with four wheel drive, do not remove the

snap ring for the four wheel drive gear unless the
snap ring is damaged.
RCPH10TLB784AAL 33
Next operation:
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Transmission drive and driven shafts - Inspect - Secondary shaft

1. Check the teeth on the gears for wear and damage. If
a tooth is badly damaged, be sure to inspect the gear
or spline that is in mesh with the damaged gear.
2. Check the splines on the secondary shaft for wear
and damage. Check the passages in the secondary
shaft to be sure that the passages are open and free
of foreign material.
3. Check the bearings for flat areas, pitting, and other
damage. Replace as necessary.
4. Check the teeth in the synchronizer assemblies for
wear and damage. Replace as necessary.
5. Check for wear or damage to the steel rings and
the bronze rings from the synchronizer assemblies.
Check the springs in the synchronizer assemblies for
wear, cracks, heat distortion, and other damage. Re-
place as necessary.
Next operation:
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Transmission drive and driven shafts - Assemble - Secondary shaft

NOTE: Before each gear is installed on the secondary shaft, make sure that the bore of the gear and the outside
diameter of the secondary shaft are completely lubricated with clean transmission oil.
NOTE: When you install snap rings on the secondary shaft, make sure that the ends of each snap ring are seated in
the snap ring groove. Do not install a snap ring so that the ends extend into an axial slot on the secondary shaft.
1. If equipped with four wheel drive, if the snap ring
was removed from the shaft, install the snap ring as
shown.
RCPH10TLB784AAL 1
2. Put the secondary shaft on the bench so that the first-

second gear end is up. You can use a vise with soft
jaws to hold the secondary shaft in position. Install
the four-wheel drive gear, if equipped.
RCPH10TLB783AAL 2
3. If equipped with four wheel drive, install the snap ring

for the four wheel drive gear.
RCPH10TLB782AAL 3
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4. Install first gear.
RCPH10TLB781AAL 4
5. This photo shows the correct relationship between

the hub and the sleeve for assembly of the first-sec-
ond synchronizer. The tabs (1) in the inside diameter
of the sleeve fit into the small recesses (2) in the out-
side diameter of the hub. The large recesses (3) in
the hub are for the detent assemblies, that are not
yet installed.
RCPH10TLB950AAL 5
6. This photo shows the correct positions of the hub, the

sleeve, the springs, the blocks, and the balls prior to
final assembly. The springs are installed in the hub,
and the blocks are on the springs. The blocks are
not yet pushed down into the sleeve and are holding
the hub up out of the sleeve. The balls are loose in
the recesses of the blocks.
RCPH10TLB951AAL 6
7. Use a punch or screwdriver to push the balls into the

blocks and to push the blocks down so that the balls
are on the flat faces of the teeth, but not into the de-
tent grooves. When all the balls are in position, push
the hub and the blocks down until the balls move into
the detent groove.
RCPH10TLB952AAL 7
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8. Install the tapered friction ring on the synchronizer

assembly.
RCPH10TLB947AAL 8
9. Use clean transmission oil to lubricate the bronze

ring (1) and the steel ring (2). Install the bronze ring
(1) and the steel ring (2)as shown.
RCPH10TLB946AAL 9
10. Install the synchronizer ring as shown. The flat sides

of the teeth must be up.
RCPH10TLB945AAL 10
11. Turn the synchronizer assembly over and install the

tapered friction ring on the other side.
RCPH10TLB947AAL 11
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12. Use clean transmission oil to lubricate the bronze

ring (1) and the steel ring (2). Install the bronze ring
(1) and the steel ring (2)as shown.
RCPH10TLB946AAL 12
13. Install the top synchronizer ring on the synchronizer

assembly. Make sure that the teeth on the top syn-
chronizer ring are aligned with the teeth on the inside
of the sleeve. Push the sleeve up until the sleeve
engages the teeth on the top 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 completely en-
gaged, the detent must hold the sleeve in this posi-
tion. Push the sleeve back down to the neutral posi-
tion, turn the synchronizer assembly over, and repeat
the procedure with the bottom synchronizer ring. If
the sleeve does not engage the teeth smoothly or
does not stay in position when moved to any of the
three positions, the synchronizer assembly has dam-
aged parts or was not assembled correctly. Disas-
semble the synchronizer assembly to find the prob-
lem.
14. Install the synchronizer ring and the first-second syn-
chronizer as an assembly. Make sure the top syn-
chronizer ring is installed so that the flat sides of the
teeth are up.
RCPH10TLB780AAL 13
NOTE: There is a groove in the bore at one end of the synchronizer hub. The synchronizer assembly must be installed
so that the groove is down.
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RCPH10TLB779AAL 14
16. Install and second gear. The teeth in the inside diam-
eter of the spacer must engage the teeth on the bot-
tom of second gear before second gear is installed.
RCPH10TLB778AAL 15
RCPH10TLB777AAL 16
Next operation:
Transmission drive and driven shafts - Adjust (21.154)
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Transmission drive and driven shafts - Adjust - Backlash

adjustment
1. Install the thrust washer and snap ring.
RCPH10TLB775AAL 1
2. Use a feeler gauge and measure the backlash be-

tween the gear and the thrust washer. Record this
measurement (a). Subtract the recorded measure-
ment (a) from 0.20 to 0.42 mm (0.0079 to 0.0165
inch) (b). Select the shim(s) required (c). Example:
Use 0.83 ± 0.11 mm (0.0327 ± 0.0043 inch) shim (s).
a. 1.14 mm 0.0449 inch

b. -0.31 mm 0.0122 inch
c. 0.83 mm 0.0327 inch
3. Remove the snap ring and thrust washer.
RCPH10TLB775AAL 2
4. Use clean transmission oil to lubricate the shim(s)

and the thrust washer. Install the shim(s). Install the
thrust washer on top of the shim(s). Make sure that
the side with the oil grooves is down.
RCPH10TLB776AAL 3
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5. Put the bearing race on the shaft.
RCPH10TLB774AAL 4
6. Use an acceptable driver to drive the bearing race

onto the secondary shaft until bearing race makes
contact with the snap ring.
RCPH10TLB785AAL 5
7. Turn the secondary shaft over so that second gear is

at the bottom. Use blocks to support the secondary
shaft. Install the fourth gear on the secondary shaft.
RCPH10TLB771AAL 6
8. This photo shows the correct relationship between

the hub and the sleeve for assembly of the third-
fourth synchronizer. The tabs (1) in the inside diam-
eter of the sleeve fit into the small recesses (2) in the
outside diameter of the hub. The large recesses (3)
in the hub are for the detent assemblies, shown in-
stalled.
RCPH10TLB811AAL 7
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9. Install the 3 sets of hub springs, hub pins, and spring

plates into the synchronizer hub. Use a punch or
screwdriver to push the spring plates as the synchro-
nizer hub is installed into the sleeve. Be sure that
the spring plates are aligned with the grooves in the
sleeve.
RCPH10TLB952AAL 8
10. Install the friction ring on each side the synchronizer

assembly.
RCPH10TLB892AAL 9
11. Use clean transmission oil to lubricate and install the

clutch ring on each side of the synchronizer assem-
bly.
RCPH10TLB891AAL 10
12. Install the top synchronizer ring on the synchronizer

assembly. Make sure that the teeth on the top syn-
chronizer ring are aligned with the teeth on the inside
of the sleeve. Push the sleeve up until the sleeve
engages the teeth on the top 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 completely en-
gaged, the detent must hold the sleeve in this posi-
tion. Push the sleeve back down to the neutral posi-
tion, turn the synchronizer assembly over, and repeat
the procedure with the bottom synchronizer ring. If
the sleeve does not engage the teeth smoothly or
does not stay in position when moved to any of the RCPH10TLB810AAL 11
three positions, the synchronizer assembly has dam-

aged parts or was not assembled correctly. Disas-
semble the synchronizer assembly to find the prob-
lem.
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13. Install the synchronizer assembly onto the shaft.
RCPH10TLB770AAL 12
14. Install the third gear on the shaft.
RCPH10TLB769AAL 13

washer. Install the thrust washer onto the shaft.
RCPH10TLB768AAL 14
16. Put the bearing in position on the secondary shaft.

Make sure that the snap ring groove is at the top.
RCPH10TLB767AAL 15
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17. Use an acceptable driver to drive the bearing onto

the secondary shaft until the bearing makes contact
with the thrust washer.
RCPH10TLB953AAL 16
NOTE: If the bearing is not very tight on the secondary shaft, parts could fall from the secondary shaft when you
install the secondary shaft in the rear housing. To prevent this, you can install a hose clamp on the output end of the
secondary shaft. This will keep the bearing in position during installation of the secondary shaft.
18. Check for correct operation of both synchronizer as-
semblies. If they do not shift smoothly, with the teeth
on the synchronizer ring aligned with the splines on
the sleeve, the re is a problem. Disassemble as nec-
essary, and correct the problem.
Next operation:
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Transmission drive and driven shafts - Disassemble - Primary shaft

1. Put the primary shaft on the bench so that the end
with the bearing attached is up. Remove the snap
ring.
RCPH10TLB954AAL 1

gear and the bearing. Install an acceptable puller on
the bearing separator. Use a shaft protector between
the puller and the end of the primary shaft. Use moly-
the end of the puller. Pull the bearing from the pri-
mary shaft.
RCPH10TLB955AAL 2
RCPH10TLB956AAL 3
RCPH10TLB957AAL 4
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5. Install a bearing separator under the lip of the bear-

ing race as shown. Install an acceptable puller on the
bearing separator. Use a shaft protector between the
puller and the end of the primary shaft. Use moly-
the end of the puller. Pull the bearing race from the
primary shaft.
RCPH10TLB958AAL 5
Next operation:
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Transmission drive and driven shafts - Inspect - Primary shaft

1. Check the teeth on the gears for wear and damage. If
a tooth is badly damaged, be sure to inspect the gear
or spline that is in mesh with the damaged gear.
2. Check the splines on the primary shaft for wear and
damage.
3. Check the bearings for flat areas, pitting, and other
damage. Replace as necessary.
Next operation:
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Transmission drive and driven shafts - Assemble - Primary shaft

1. Use an acceptable driver to drive the bearing race all
the way onto the primary shaft.
RCPH10TLB959AAL 1

washer. Install the thrust washer so that the side
with the oil grooves is down.
RCPH10TLB957AAL 2
3. Put the bearing into position so that the snap ring

groove on the outside diameter of the bearing is at
the top.
RCPH10TLB956AAL 3
4. Use an acceptable driver to drive the bearing onto the

primary shaft until the bearing makes contact with the
thrust washer.
RCPH10TLB960AAL 4
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RCPH10TLB954AAL 5
Next operation:
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Transmission drive and driven shafts - Disassemble - Reverse shaft

1. The bearings are the only serviceable parts on the re-
verse shaft. If you remove the bearings, use a shaft
protector between the puller and the end of the re-
verse shaft. Use molydisulfide grease to lubricate the
shaft protector and the end of the puller. (1)Bearing,
(2) Reverse shaft
RCPH10TLB050ABL 1
Next operation:
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Transmission drive and driven shafts - Inspect - Reverse shaft

1. Check the teeth on the gears for wear and damage.
If a tooth is badly damaged, be sure to inspect the
gear that is in mesh with the damaged gear. Check
the bearings for flat areas, pitting, and other damage.
Replace as necessary.
Next operation:
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Transmission drive and driven shafts - Assemble - Reverse shaft

1. Use an acceptable driver to drive each bearing onto
the reverse shaft until the bearing makes contact with
the shoulder on the reverse shaft.
Next operation:
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Transmission drive and driven shafts - Disassemble - Oil pump

NOTE: Bolts (6), O-Rings, bushings and seals are the only serviceable components in the oil pump. Complete dis-
assembly of the oil pump is shown for reference only.
1. Remove the O-ring.
RCPH10TLB983AAL 1
2. Remove the two Allen head bolts that fasten the

pump support to the pump housing.
RCPH10TLB984AAL 2
3. Separate the pump support from the pump housing.
RCPH10TLB985AAL 3
4. Remove the large gear from the pump housing.
RCPH10TLB986AAL 4
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NOTE: Install a plastic plug in the bearings to keep the bearings from falling out when the small gear is removed from
the pump housing.
5. Remove the small gear from the pump housing.
RCPH10TLB987AAL 5
NOTE: Be careful when removing the plastic plug from the small gear the needle bearings will fall out. Make a record
of the number of needle bearings remove from the small gear for use during assembly.
6. Remove the seal from the pump housing.
RCPH10TLB988AAL 6
7. Turn the pump housing over and use blocks to sup-

port the pump housing. Use an acceptable driver to
drive the bushing from the bore of the pump housing.
RCPH10TLB989AAL 7
8. Support the large gear on blocks as shown. Use a

punch and a hammer to drive the bushing from the
large gear.
RCPH10TLB994AAL 8
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9. Use an acceptable driver to push the needle bearing

out of the small gear.
RCPH10TLB996AAL 9
10. Remove the shaft for the small gear only if the shaft
is damaged. The shaft will probably be difficult to
remove.
RCPH10TLB993AAL 10
11. Use a blind hole puller and a slide hammer to pull the
bushing from the shaft of the pump support.
RCPH10TLB997AAL 11
12. Remove the roll pin for the torque converter relief
valve.
RCPH10TLB999AAL 12
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13. Remove the plug, the spring, and the ball for the
torque converter relief valve.
RCPH10TLB001ABL 13
14. Remove the roll pin for the oil pump relief valve. Be
very careful because the large amount of spring ten-
sion will force the parts out when the roll pin is re-
moved.
RCPH10TLB002ABL 14
15. Remove the plug, the spring, the pin, and the plunger
for the oil pump relief valve.
RCPH10TLB038ABL 15
Next operation:
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Transmission drive and driven shafts - Inspect - Oil pump

1. Inspect the large gear and the small gear for wear
and damage. If the teeth on a gear have scoring,
excessive wear, or sharp edges, use a new gear.
Check for damage to the lugs on the large gear. If
there is damage, check the hub on the torque con-
verter for similar damage. Replace the large gear
and the torque converter as necessary.
2. Inspect the gear pockets in the pump housing for
wear or damage. If the gear pockets have scoring
or excessive wear, use a new oil pump.
3. Inspect the splines on the shaft for wear and damage.
If you find damage, inspect the part that is installed
on the shaft.
4. Inspect all passages to be sure that the passages are
open and free of foreign material.
5. Check the needle bearing for wear, pitting, or other
damage.
6. Inspect the parts of the torque converter relief valve
and the oil pump relief valve for wear and damage.
Next operation:
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Transmission drive and driven shafts - Assemble - Oil pump

1. Install the plunger for the oil pump relief valve.
RCPH10TLB042ABL 1
2. Install the pin for the oil pump relief valve. The ma-
chined end of the pin must be toward the plunger.
Make sure that the pin goes into the bore of the
plunger.
RCPH10TLB041ABL 2
RCPH10TLB040ABL 3
4. Install the plug.
RCPH10TLB039ABL 4
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5. This step will be difficult because the spring will be

under heavy tension. Push the plug in until the plug
is to the inside of the hole for the roll pin. Install the
roll pin.
RCPH10TLB002ABL 5
6. Install the ball, the spring, and the plug for the torque
converter relief valve. Make sure that the hole in the
plug is aligned with the hole for the roll pin.
RCPH10TLB001ABL 6
7. Install the roll pin through the holes in the pump sup-
port and the hole in the plug.
RCPH10TLB003ABL 7
8. Use an acceptable driver to install a new bushing in

the shaft of the pump support.
RCPH10TLB998AAL 8
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9. Use an acceptable driver to install a new needle

bearing in the small gear. Push the needle bearing
until the needle bearing is approximately centered in
the bore of the gear.
RCPH10TLB996AAL 9
10. If the shaft for the small gear was removed, clean the
mating surfaces and apply either Loctite 640 (green)
or Loctite 642 (amber) before installation.
RCPH10TLB993AAL 10
11. Support the large gear on blocks so that the side with
the lugs is down. Use an acceptable driver to push
the new bushing to the end of the bore.
RCPH10TLB995AAL 11
12. Put a new bushing into position so that the recess (1)
in the bushing is aligned with the oil drain hole (2) in
the pump housing.
RCPH10TLB990AAL 12
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13. Use an acceptable driver to install the bushing.
RCPH10TLB992AAL 13
14. Use an acceptable driver to install a new seal in the

end of the pump housing.
RCPH10TLB991AAL 14
15. Use clean transmission oil to lubricate the small gear,

the needle bearing, and the bore in the pump hous-
ing. Install the small gear on the shaft in the pump
housing. Install the same number of needle bearings
that were removed between the small gear and the
shaft.
RCPH10TLB987AAL 15
16. Use clean transmission oil to lubricate the large gear,

the bushing in the large gear, and the bore in the
pump housing. Install the large gear so that the side
with the lugs is down.
RCPH10TLB986AAL 16
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21.154 / 80
17. Install the pump support on the pump housing. Make

sure that all the bolt holes are aligned.
RCPH10TLB985AAL 17
18. Install the two Allen head bolts to fasten the pump
support to the pump housing. Tighten the Allen head
bolts until they are just snug.
RCPH10TLB984AAL 18
19. Install a large worm gear clamp (radiator hose clamp)

around the outside of the pump housing and the
pump support. The clamp must cover the joint be-
tween the two parts and be in contact with both parts.
Tighten the clamp. Tap the housing with a soft ham-
mer. Tighten the clamp again. Tap the housing
again with a soft hammer. Tighten the clamp again.
Tighten the Allen head bolts to 10 Nm (89 pound-
inches). Remove the clamp.
20. Put the oil pump on a clean work surface so that the
pump housing is up. Insert a small screwdriver or
punch through the hole in the torque converter hub
and rotate the large gear by pushing against one of
the lugs. The large gear must rotate freely. If the
large gear does not rotate freely, loosen the Allen
head bolts and repeat step 340. If the large gear
rotates freely, fill the oil pump with clean transmission
oil and rotate the large gear three revolutions before
you install the oil pump on the transmission.
47365539 08/07/2012
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RCPH10TLB983AAL 19
Next operation:
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Transmission drive and driven shafts - Disassemble - Four wheel

drive shaft
1. There is a pipe plug at the bottom of the hole in the
end of the shaft (see arrow). DO NOT remove the
pipe plug unless the pipe plug is damaged.
RCPH10TLB883AAL 1
2. Use an acceptable tool to press the spring retainer

down until you have access to the snap ring (see ar-
row). Remove the snap ring from the groove. Re-
lease the tension and remove the tool.
RCPH10TLB884AAL 2
NOTE: The tool used in the photo above is a piece of round tubing with a rectangular access hole cut out to provide
access to the snap ring.
3. Remove the snap ring from the shaft.
RCPH10TLB885AAL 3
47365539 08/07/2012
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RCPH10TLB886AAL 4
5. Remove the special washer.
RCPH10TLB887AAL 5
6. Remove the springs.
RCPH10TLB888AAL 6
RCPH10TLB889AAL 7
47365539 08/07/2012
21.154 / 84
8. Remove the two O-rings from the shaft.
RCPH10TLB890AAL 8
9. Remove the two Teflon sealing rings from the shaft.
RCPH10TLB890AAL 9
Next operation:
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Transmission drive and driven shafts - Inspect - Four wheel drive

shaft
1. Inspect the lugs on the sleeve for peening or other
damage. If you find damage to the lugs, also inspect
the four-wheel drive clutch gear.
2. Check the splines on the shaft and inside the sleeve
for wear and damage.
3. Check the passages in the shaft to be sure that the
passages are open and free of foreign material.
4. Check the springs for wear, cracks, heat distortion,
and other damage. Replace as necessary.
Next operation:
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Transmission drive and driven shafts - Assemble - Four wheel

drive shaft
NOTE: Special tools used up to step 6 are from the tool set CAS2771A, standard transmission without rear pump
drive.
1. Install new O-rings on the shaft. Use clean transmis-
sion oil to lubricate the O-rings.
RCPH10TLB890AAL 1
2. Install the CAS2771-2 expander/protector on the

shaft.
RCPH10TLB894AAL 2
NOTE: For clarity, the following photo does not show the use of a heat resistant glove. To prevent injury be sure to
wear a heat resistant glove when installing the Teflon sealing ring.
CAS2771-2 expander/protector.
RCPH10TLB895AAL 3
47365539 08/07/2012
21.154 / 87
4. Install the CAS2327 pusher over the expander/pro-

RCPH10TLB896AAL 4
5. Install the end of the CAS2771-7 seal compressor

RCPH10TLB897AAL 5

from the shaft.
RCPH10TLB898AAL 6
7. Place the CAS2771-3 spacer against the end of the

shaft.
RCPH10TLB899AAL 7
47365539 08/07/2012
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8. Slide the CAS2771-2 expander/protector over the

CAS2771-3 spacer. The expander/protector will stop
in the correct position to install the sealing ring in the
groove.
RCPH10TLB900AAL 8
NOTE: For clarity, the following photo does not show the use of a heat resistant glove. To prevent injury be sure to
wear a heat resistant glove when installing the Teflon sealing ring.
CAS2771-2 expander/protector.
RCPH10TLB900AAL 9
10. Install the CAS2327 pusher over the expander/pro-

RCPH10TLB902AAL 10
11. Install the end of the CAS2771-1 seal compressor

RCPH10TLB903AAL 11
47365539 08/07/2012
21.154 / 89
from the shaft.
RCPH10TLB904AAL 12
13. Install the sleeve on the shaft. Be careful not to dam-

age the Teflon sealing rings and the O-rings while in-
stalling the sleeve.
RCPH10TLB889AAL 13
14. Install the springs.
RCPH10TLB888AAL 14
15. Install the special washer.
RCPH10TLB887AAL 15
47365539 08/07/2012
21.154 / 90
16. Install the spacer onto the shaft.
RCPH10TLB886AAL 16
17. Install the snap ring onto the shaft.
RCPH10TLB885AAL 17
18. Use an acceptable tool to press the spring retainer

down until you have access to the snap ring groove
(see arrow). Install the snap ring in the groove. Re-
lease the tension and remove the tool. Make sure
that the snap ring is seated in the recess in the spring
retainer.
RCPH10TLB884AAL 18
NOTE: The tool used in the photo above is a piece of round tubing with a rectangular access hole cut out.
19. If the pipe plug at the bottom of the hole in the end
of the shaft (see arrow) was removed, apply Loctite
242 or Loctite 262 to the threads of the new pipe plug
before installation. Tighten the pipe plug to a torque
of 30 Nm (266 pound-inches).
RCPH10TLB004ABL 19
Next operation:
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Index
Transmission - 21

Transmission drive and driven shafts - Adjust - Backlash adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Transmission drive and driven shafts - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Transmission drive and driven shafts - Assemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Transmission drive and driven shafts - Assemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Transmission drive and driven shafts - Assemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Transmission drive and driven shafts - Assemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Transmission drive and driven shafts - Assemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Transmission drive and driven shafts - Disassemble - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Transmission drive and driven shafts - Disassemble - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Transmission drive and driven shafts - Disassemble - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Transmission drive and driven shafts - Disassemble - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Transmission drive and driven shafts - Disassemble - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Transmission drive and driven shafts - Disassemble - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Transmission drive and driven shafts - Exploded view - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Transmission drive and driven shafts - Exploded view - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transmission drive and driven shafts - Exploded view - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission drive and driven shafts - Exploded view - Shift rod and forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transmission drive and driven shafts - Inspect - Four wheel drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Transmission drive and driven shafts - Inspect - Input shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Transmission drive and driven shafts - Inspect - Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Transmission drive and driven shafts - Inspect - Primary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Transmission drive and driven shafts - Inspect - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Transmission drive and driven shafts - Inspect - Secondary shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
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Transmission - 21
Powershift transmission internal components - 155
580N
580SN WT
580SN
590SN
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Contents
Transmission - 21
FUNCTIONAL DATA
Shaft assemblies
Exploded view - H-Type - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch
Exploded view - H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Shaft assemblies
Disassemble - S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble -S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disassemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Assemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Disassemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Assemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Disassemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Assemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Disassemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Assemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Clutch
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Back side measurement 81
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Front side measurement 86
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Dimension "D" measurement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Neutral position measure-
ment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Check - S-Type (SPS Power Syncro) - Speed gears switches - Checking procedure . . . . . . . . . . . . . . . 95
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Transmission - Powershift transmission internal components
Shaft assemblies - Exploded view - H-Type - Reverse shaft

Reverse shaft
1. Bearing 11. Thrust plate 21. Split pin 31. Clutch drive plates
2. Bearing 12. Clutch drive plates 22. Split pin 32. Thrust plate
3. Teflon seal 13. Clutch plates 23. Teflon seal ring 33. Lock ring
4. Snap ring 14. Snap ring 24. O-ring 34. Retaining plate
5. Bearing 15.Lock washer 25. Clutch piston 35. Gear
6. Spacer 16. Spring 26. Sleeve 36. Needle cage
7. Needle cage 17. Sleeve 27. Spring 37. Retaining plate
8. Gear 18. Clutch piston 28. Lock washer 38. Bearing
9. Retaining plate 19. Teflon seal ring 29. Snap ring 39. Snap ring
10. Lock ring 20. O-ring 30. Clutch plates 40. Teflon seal ring
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RCPH10TLB019GAL 1
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Clutch - Exploded view - H-Type

1. Seal 8. Gear 15. Snap ring 22. Shaft
2. Seal 9. Lock ring 16. Retaining washer 23. Spring pin
3. Bearing 10. Thrust plate 17. Spring 24. Bearing
4. Gear 11. Clutch discs 18. Sleeve 25. Teflon seal ring
5. Lock ring 12. Reaction plates 19. Clutch piston
6. Washer 13. Washer 20. Teflon seal ring
7. Roller retainer 14. Spacer 21. Teflon seal ring
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RCPH10TLB018GAL 1
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Shaft assemblies - Disassemble - S-Type (SPS Power Synchro) -

Rear cover - shafts
NOTE: To remove shaft B and C, remove the front half-housing, the parking brake, the rear cover, the bearing snap
ring of the secondary shaft and the switches group
NOTE: Steps 3 through 5 are for machines with a parking brake.
(2).
RCPH10TLB109AAL 1
2. Remove the parking brake group.
RCPH10TLB045ACL 2
3. Remove O-Ring (1)Remove the 7 screws (2). Re-

move the flange (3). Remove the assembled PTO
shaft (4)
RCPH10TLB050ACL 3
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4. Remove the 4 screws (1)and the 3 screws (2). Re-

move the rear cover (3).
RCPH10TLB049ACL 4
NOTE: Steps 6 through 8 are for machines without a parking brake.

5. Remove the 5 screws (1), the 3 screws (2)and the 2
screws (3).
RCPH10TLB255ACL 5
6. Remove the rear cover (1)and the PTO shaft (2).
RCPH10TLB256ACL 6
7. Remove PTO shaft.
RCPH10TLB193ACL 7
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8. If necessary, remove teflon seal ring. It may be nec-

essary to cut the ring.
RCPH10TLB105AAL 8
9. Remove snap ring.
RCPH10TLB257AAL 9

the PTO shaft.
RCPH10TLB106AAL 10
11. Remove shims (1). Remove bearing snap ring (2).
RCPH10TLB194ACL 11
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12. Attach lifting bracket 380100088 to the shafts, re-

move them from the transmission.
RCPH10TLB145AAL 12
Next operation:
Shaft assemblies - Assemble (21.155)
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Shaft assemblies - Assemble -S-Type (SPS Power Synchro) - Rear

cover - shafts
1. Assemble the 4WD shaft. Remove the secondary
shaft and the primary shaft.
RCPH10TLB719AAL 1
2. Assemble the input shaft. Assemble the idler shaft.

Install the front half housing on the rear half housing.
Tighten the screws. Assemble the switches group.
RCPH10TLB720AAL 2
3. Push the secondary shaft toward the rear of the rear

housing so that there is clearance between the snap
ring groove and the rear housing. Assemble the
bearing snap ring on the secondary shaft Assemble
the shims on the secondary shaft.
RCPH10TLB732AAL 3
4. If you change bearing of the secondary shaft or rear

front-housing calculate the amount of shims to be
inserted between rear cover and rear half-housing.
RCPH10TLB732AAL 4
5. Rear cover. Determine the dimension Y.
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6. Rear front-housing.. Determine the dimension Z.

7. Prescribed end float (between rear cover and rear
half-housing) --> 0 ÷ 0,1 mm. Select an amount of
shims S , among the range of available shims see ta-
ble in next step), to make sure there is the prescribed
end float. S= Y-Z mm
RCPH10TLB257ACL 5
8. Select the shim of thickness value (S) among the

range of available shims. Note: choose the shim
(S) so that is guaranteed an end float of 0 ÷ 0.1 mm
between rear cover and rear half-housing
RCPH10TLB078ACL 6
9. Assemble the shims.
RCPH10TLB257ACL 7
10. Heat the bearing to 60 - 80 °C (140.0 - 176.0 °F)for

5 minutes. Assemble bearing on the shaft PTO.
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11. Assemble snap ring..
RCPH10TLB257AAL 8
12. For the assembly of teflon seal ring follow operations

from step 19 to step 23 using the following tools.
CA716225 (without shim) CA715497 CA715356.
RCPH10TLB087ACL 9
NOTE: Steps 13 through 15 are for machines without the parking brake.
13. Assemble PTO shaft (1)into the rear cover (2).
RCPH10TLB193ACL 10
14. Apply a thin film of sealant on the edge of the rear

cover. Assemble the rear cover group. Make sure
that the pin is correctly installed both in the rear hous-
ing and through the hole in the rear cover.
RCPH10TLB256ACL 11
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15. Tighten the 5 screws (1)the 3 screws (2)and the 2

screws (3)to fasten the rear cover to the rear half
housing. If necessary, tap the rear cover with a soft
faced hammer to close the gap between the rear
half housing and the rear cover before tightening
the screws. Tightening torque Powershift transmis-
sion - Torque (21.113). Assemble the O-Ring (4).
RCPH10TLB255ACL 12
NOTE: Steps 16 through 22 are for machines with the parking brake.
16. Clean the cover (1). Apply a thin film of sealant on
the edge of the rear cover.
RCPH10TLB168ACL 13
17. Clean the rear half-housing. Assemble the O-Ring

(1)on the rear half-housing.
RCPH10TLB057ACL 14
18. Make sure that the pin (1)is correctly installed both
in the rear housing and through the hole in the rear
cover. Tighten the 4 screws (2)and the 3 screws
(3)to fasten the rear cover to the rear half hous-
ing. Tightening torque Powershift transmission -
Torque (21.113).
RCPH10TLB049ACL 15
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19. Clean the flange.
RCPH10TLB166ACL 16
20. Apply a thin film of sealant on the edge of the flange.
RCPH10TLB167ACL 17
21. Assemble the assembled PTO shaft (1)into the trans-

mission. Assemble the flange (2). Tighten the 7
screws (3)to fasten the flange to the cover. Tighten
torque Powershift transmission - Torque (21.113).
Assemble the O-Ring (4).
RCPH10TLB002AAN 18
22. Assemble the parking brake group.
RCPH10TLB001AAN 19
Next operation:
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Shaft assemblies - Disassemble -S-Type (SPS Power Synchro)

- Gear pistons
NOTE: To remove gear and neutral piston, remove the parking brake group and rear cover and secondary shaft
lubrication pipe.
1. Remove the O-Rings.
RCPH10TLB062ACL 1
NOTE: O-rings cannot be re-used. Replace O-rings during assembly.

2. Remove 2nd (1)and 4th (2) gear pistons.
RCPH10TLB063ACL 2
NOTE: Use a M4 screw to remove the pistons. If replacement of pistons is needed see following step.
3. If dimension difference between the new piston and
the replaced one is more than 0.07 mm, shift rails
and switches adjustment is required.
RCPH10TLB217ACL 3
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4. 4th gear pistons - ø36 mm. If the replacement is

needed cut the seal ring and remove it. Remove the
O-Ring
RCPH10TLB251ACL 4
5. 2nd gear pistons- ø42 mm. If the replacement is

needed cut the seal ring and remove it. Remove the
O-Ring
RCPH10TLB251ACL 5
6. If one of the following parts is replaced : synchro-

nizer, shift rails, forks, secondary shaft, secondary
shaft gears or half-housings, the shims adjusting
must be revised. Remove the screw (1). Remove
the bushing (2). Collect the shims (3).
RCPH10TLB064ACL 6
7. Remove the screws (1). Remove the locking plugs.

(2).
RCPH10TLB065ACL 7
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8. Remove the plugs (1). See next step.
RCPH10TLB058ACL 8
9. Remove the screws (1). Remove the oil circuit plate

(2). Remove the O-Rings (3). Remove plugs by
blowing in air (just enough to pull out the plugs)
through the hole as shown in figure (see arrows).
RCPH10TLB081ACL 9
NOTE: Possible oil leakage. Carefully follow all the safety procedures indicated in this manual and in the vehicle
manual.
10. Plug (3). ø52 mm. Remove the O-Ring.
RCPH10TLB172ACL 10
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11. Plug (5). ø47 mm. Remove the O-Ring.
RCPH10TLB172ACL 11
12. Remove the NEUTRAL pistons.
RCPH10TLB059ACL 12
NOTE: Use a M4 screw to remove the pistons. If the replacement is needed remove the seal and O-Ring. See step
4 to disassemble the seals. If replacement of pistons is needed see step 15.
13. Remove 1st (1)and 3rd (2)gear pistons. If replace-
ment of pistons is needed see following step.
RCPH10TLB060ACL 13
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14. If dimension difference between the new piston and

the replaced one is more than 0.07 mm, shift rails
and switches adjustment is required.
RCPH10TLB217ACL 14

(1)must be revised. If necessary remove the screw
(2)and collect the shims (1). If the replacement is
needed remove the seal and O-Ring (3). See step 4
and 5 to disassemble the seals.
RCPH10TLB066ACL 15

(1)must be revised. Remove the screw (2). Remove
the bushing (3). Collect the shims (1).
RCPH10TLB061ACL 16
Next operation:
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Shaft assemblies - Assemble -S-Type (SPS Power Synchro) - Gear

pistons
1. 4th gear pistons - ø36 mm. Assemble the O-Ring
into the piston.
RCPH10TLB233ACL 1
2. Assembly seal ring (1)into the piston (2).
RCPH10TLB048ACL 2
3. Slide the expander/protector tool onto the piston (1).

The expander/protector will stop in the correct posi-
tion to install the seal ring in the groove.
RCPH10TLB234ACL 3
4. Heat the Teflon seal ring (1)to 60 - 80 °C (140.0 -

176.0 °F)for 5 minutes. Install the teflon seal ring
onto the expander/protector.
RCPH10TLB196ACL 4
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5. Install the pusher tool over the expander/protector

and slide the seal ring until it reaches the groove in
the shaft. Remove the pusher, expander/protector,
RCPH10TLB197ACL 5
6. Install the end of the seal compressor with the deep

chamfer onto the piston and over the sealing ring.
Use a back and forth twisting motion to allow the seal
compressor to slip over the top of the sealing ring and
seat the sealing ring into the groove. Be careful not to
damage the seal ring. After the sealing ring is seated
in the groove, leave the seal compressor in place for
seal ring has cooled, remove the seal compressor
from the piston.
RCPH10TLB140ACL 6
7. 2nd gear pistons - ø42 mm. Assemble the O-Ring

into the piston.
RCPH10TLB233ACL 7
8. Assembly seal ring (1)into the piston (2).
RCPH10TLB048ACL 8
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9. For the installation of the seal ring (1), repeat the

operations from sequence 3 to sequence 6, using
the following tools: expander/protector, pusher, and
gauger service tool.
RCPH10TLB234ACL 9

must be revised.
RCPH10TLB046ACL 10
11. Assemble the special tool on the shaft rail. Assemble

the shims.
RCPH10TLB266ACL 11
12. Assemble the bushing (1). Assemble the bushing as

shown in figure.
RCPH10TLB267ACL 12
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13. Bushing figure.
RCPH10TLB067ACL 13
14. Remove the special tool.
RCPH10TLB269ACL 14
15. Check the switches have been proper assembled

and adjust the control gear shaft and than assem-
ble the screw (1)with sealant. Tighten the screws
(1)Tightening torque Powershift transmission -
Torque (21.113).
RCPH10TLB270ACL 15
16. Engage the 3rd speed gear and check that the bush-
ing top is in range.
47365539 08/07/2012
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must be revised.
RCPH10TLB047ACL 16
18. Assemble the special tool on the shift rail. Assemble

the shims (1). Assemble the bushing (2). Assemble
the bushing as shown in figure.
RCPH10TLB146ACL 17
19. Assemble as shown.
RCPH10TLB068ACL 18
20. Check the switches have been properly assembled

adjust control gear shaft and then assemble the
screw (1)with sealant. Tighten the screws (1)Tight-
ening torque Powershift transmission - Torque
(21.113).
RCPH10TLB147ACL 19
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21. Engage the 4th speed gear and check that bushing
top is in the range as shown in next figure.
RCPH10TLB148ACL 20

must be revised. Assemble the shims onto the
screw . Assemble the screw with sealant.
RCPH10TLB066ACL 21
23. Tighten the screws into the piston. Tightening torque

Powershift transmission - Torque (21.113).
RCPH10TLB219ACL 22
24. Use a special tool to insert 3rd gear pistons (1). Use
a special tool to insert 1st gear pistons (2).
RCPH10TLB235ACL 23
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RCPH10TLB069ACL 24
26. Assemble 3rd and 1st gear pistons.
RCPH10TLB236ACL 25
27. Push the piston into the seat using a soft tool mate-
rial. Remove the special tools.
RCPH10TLB237ACL 26
28. Assemble as shown. Seal ring into the NEUTRAL

piston (16).
RCPH10TLB048ACL 27
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29. Assemble the O-Ring (1)into the NEUTRAL piston

. For the introduction of the seal ring , repeat the
operations from sequence 3 to sequence 6, using
the following tools: expander/protector, pusher and
gauger service tool.
RCPH10TLB196ACL 28
30. Seal ring into the NEUTRAL piston.
RCPH10TLB048ACL 29
31. Assemble the O-Ring into the NEUTRAL piston . For

the introduction of the seal ring , repeat the opera-
tions from sequence 3 to sequence 6, using the fol-
lowing tools: expander/protector, pusher and gauger
RCPH10TLB196ACL 30
32. 3N4 piston . Use special tool to insert the NEUTRAL

pistons . 1N2 piston . Use a special tool to insert the
NEUTRAL pistons.
RCPH10TLB170ACL 31
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33. Push the piston in your seat using a soft tool material.
Remove the special tool.
RCPH10TLB171ACL 32
RCPH10TLB070ACL 33
35. Plug (3). ø52 mm. Assemble the O-Ring.
RCPH10TLB172ACL 34
36. Plug (5). ø47 mm. Assemble the O-Ring.
RCPH10TLB172ACL 35
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37. Assemble the plug.
RCPH10TLB173ACL 36
38. Assemble the locking plugs (2). Tighten the screws

(1)Tightening torque Powershift transmission -
Torque (21.113).
RCPH10TLB065ACL 37
39. Assemble group (B).
RCPH10TLB174ACL 38
40. Rear cover side: Use dealer supplied special tools

to insert 2nd and 4th gear pistons . Put the piston
into the tool and push out about 3 mm to allow the
centering on half housing.
RCPH10TLB144ACL 39
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41. Place the tool with piston on the half-housing. Push

the piston in its seat using a soft tool material. Re-
move the special tools.
RCPH10TLB145ACL 40
42. Assemble the O-Rings.
RCPH10TLB062ACL 41
43. Assemble the rear cover.
RCPH10TLB049ACL 42
Next operation:
Clutch - Measure (21.155)
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Shaft assemblies - Disassemble - S-Type (SPS Power Synchro)

- Shafts A - D
(2).
RCPH10TLB109AAL 1
RCPH10TLB110AAL 2
RCPH10TLB111AAL 3
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4. Install a bearing separator under the gear as shown

(do not install the bearing separator between the
gear and the bearing). Use a puller on the bearing
separator and insert a shaft protector between the
puller and the end of the input shaft.
RCPH10TLB112AAL 4
RCPH10TLB113AAL 5
RCPH10TLB117AAL 6
7. Remove the gear.
RCPH10TLB115AAL 7
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RCPH10TLB116AAL 8
RCPH10TLB262AAL 9
RCPH10TLB262AAL 10
11. Remove lock ring.
RCPH10TLB117AAL 11
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12. Use pry bars to lift and to remove the thrust plate.
RCPH10TLB118AAL 12
13. Remove the clutch plates and the clutch discs.
RCPH10TLB119AAL 13
14. Place a mark below the groove on the clutch housing.
RCPH10TLB120AAL 14
15. Place a mark on each thrust plate and the lock ring.
RCPH10TLB263AAL 15
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RCPH10TLB121AAL 16
RCPH10TLB264AAL 17
RCPH10TLB121AAL 18
RCPH10TLB122AAL 19
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RCPH10TLB265AAL 20
21. Use compressed air in the piston pressure port to

remove the piston.
RCPH10TLB123AAL 21
RCPH10TLB266AAL 22
23. Turn the clutch housing over, remove the teflon seal
rings.
RCPH10TLB124AAL 23
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RCPH10TLB267AAL 24

end of the input shaft. Remove the bearing.
RCPH10TLB125AAL 25
26. Remove the bearing and thrust washer.
RCPH10TLB126AAL 26
27. Remove gear.
RCPH10TLB303AAL 27
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RCPH10TLB127AAL 28
29. Repeat steps 9 to 22 to disassemble the clutch.

30. Check the sealing ring grooves (large and small) for
wear and damage if necessary. Use new parts as
required.
31. Check on the output shaft for wear and damage.
Check oil passages in the output shaft to be sure that
the passages are open and free of foreign material.
32. Check the ball bearings and the needle bearings for
flat areas, pitting, and other damage. Use new parts
as required.
33. If the clutch discs are to be used again, keep the
clutch packs in the same previous assembly order
separate and record which clutch pack goes with
each clutch. Use new parts as required.
RCPH10TLB804AAL 29
34. Use a straight edge to check each clutch drive plate

and each clutch plate to be sure each part is flat. If
they are not flat a new part must be installed dur-
ing assembly. If the clutch plates are smooth or al-
most smooth, use new parts during assembly. If the
friction material is damaged or appears burned, use
new parts during assembly. Also, check the splines
for wear. Inspect the clutch drive plate for pitting,
scoring, or other damage. If there is any damage,
use new parts during assembly. If you will be us-
ing new clutch plates, soak the clutch plates in clean
transmission oil for at least an hour before assem-
bly. If you are using the old clutch plates, make sure
that the contact surfaces are coated with transmis- RCPH10TLB943AAL 30
sion oil before assembly, check the wear conditions

(see chart below). If it is 50% compared to the nom-
inal value it is suggested its replacement.
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35. Inspect the bore and the shaft in the input shaft hous-
ing for damage that will cause leakage when the
clutch is assembled. Check the slots in the side of
the input shaft housing for damage from the tangs
on the clutch drive plates. Use new parts as required
during assembly.
FWD-RVS Gear Clutch *Under load of 163 kg (359.4 lb)

Clutch pack CA149306
Number of clutch steel plates 6
Nominal clutch plate thickness 2.4 ±0.05 mm
Nominal clutch kit thickness *29.00 - 29.20 mm
Maximum clutch plate wear (each side) 0.35 mm

end of the reverse shaft. Remove the bearing.
RCPH10TLB128AAL 31
37. Turn the shaft over and insert a shaft protector be-
tween the puller and the end of the reverse shaft.
Remove the bearing.
RCPH10TLB268AAL 32
Next operation:
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Shaft assemblies - Assemble - S-Type (SPS Power Synchro) -

Shafts A - D
1. Assemble new teflon ring and relevant inner O-rings,
respectively into the piston outer and inner seats.
RCPH10TLB266AAL 1
2. Apply a thin film of transmission oil on the sealing

rings just inserted.
RCPH10TLB198AAL 2
3. Insert clutch piston with 380001926 clutch pack pis-

ton installer.
RCPH10TLB931AAL 3
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4. Assemble sleeve.
RCPH10TLB116AAL 4
5. Assemble spring and lock spring cover.
RCPH10TLB122AAL 5
6. Lower the lock spring cover. Insert lock ring Use tool
380100109 or CAS2379.
RCPH10TLB121AAL 6
7. Insert pin.
RCPH10TLB129AAL 7
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8. Insert thrust washer.
RCPH10TLB130AAL 8
9. Insert needle cage.
RCPH10TLB131AAL 9
10. To assemble the clutch pack start with the gear on

the bench. Install the clutch plate lock ring so that
the reference mark on top of the plate made during
disassembly is facing towards the gear.
RCPH10TLB132AAL 10
11. Assemble clutch plates and clutch drive plates on the

gear . The assembled clutch pack must contain six
clutch drive plates and six clutch plates.
RCPH10TLB133AAL 11
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12. Locate the pack assembly by means of two screw-

drivers.
RCPH10TLB134AAL 12
13. Assemble lock ring and washer.
RCPH10TLB135AAL 13
14. Heat the bearing to ] 80 - 100 °C (176.0 - 212.0 °F)

Assemble bearing.
RCPH10TLB135AAL 14
RCPH10TLB136AAL 15
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gear, spacer, bearing, and snap ring installed on the input shaft.
16. Install the spacer and protector from kit 380040161
onto the input shaft with the chamfered end facing in.
RCPH10TLB140AAL 16
17. Slide the 380001428 expander/protector onto the in-

put shaft and over the spacer. The expander/protec-
tor will stop in the correct position to install the seal
ring in the groove.
RCPH10TLB826AAL 17
18. Heat the Teflon seal ring to 60 - 80 °C (140.0 - 176.0

°F) for 5 minutes. Install the teflon seal ring onto the
expander/protector.
RCPH10TLB826AAL 18

tector and slide the seal ring until it reaches the
groove in the shaft. Remove the pusher, ex-
pander/protector, and spacer from the shaft.
RCPH10TLB830AAL 19
47365539 08/07/2012
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seal ring. Use a back and forth twisting motion to
RCPH10TLB831AAL 20
seal ring. Leave the seal compressor in place for
from the shaft.
RCPH10TLB841AAL 21
NOTE: Repeat steps 1 through 13 for the other shaft

side with the oil grooves is down.
RCPH10TLB170AAL 22
23. Heat the bearing to 80 - 100 °C (176.0 - 212.0 °F)Use

a suitable driver to drive the bearing onto the input
shaft until the bearing makes contact with the thrust
washer.
RCPH10TLB211AAL 23
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24. Assemble snap ring. Using two pry bars lift the bear-
ings toward the snap ring to have clearance between
gear and bearing.
RCPH10TLB169AAL 24
25. Assemble the teflon seal rings as follows: place

the 380001929 spacer into the 380001933 ex-
pander/protector.
RCPH10TLB897AAL 25

spacer onto the shaft. The expander/protector will
stop in the correct position to install the seal ring in
the groove.
RCPH10TLB899AAL 26
27. Heat the Teflon seal ring to 60 - 80 °C (140.0 - 176.0

°F) for 5 minutes. Install the teflon seal ring onto the
expander/protector.
tector and slide the seal ring until it reaches the
groove in the shaft. Remove the pusher, ex-
pander/protector, and spacer from the shaft.
RCPH10TLB902AAL 27
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Be careful not to damage the seal ring. After the
RCPH10TLB904AAL 28
seal ring. Leave the seal compressor in place for
from the shaft.
RCPH10TLB904AAL 29
NOTE: For the introduction of the other three teflon rings, repeat the operations from sequence 27 to sequence 31,
using the following spacer rings: 380001931 for the 2nd teflon ring, 380001930 for the 3rd teflon ring, 380001929 for
the 4th teflon ring.
31. See the illustration. Apply compressed air of approx-
imately 6 bar to the forward clutch passage. Listen
to hear the forward piston moving to lock the forward
clutch pack. Try to move the forward gear. The for-
ward gear must not turn on the input shaft. Try to
move the reverse gear. The reverse gear must turn
freely on the input shaft. If the clutches do not work
correctly, disassemble the clutches to find the prob-
lem. RCPH10TLB054GAL 30
32. Apply compressed air of approximately 6 bar to the

reverse clutch passage. Listen to hear the reverse
piston moving to lock the reverse clutch pack. Try to
move the reverse gear. The reverse gear must not
turn on the input shaft. Try to move the forward gear.
The forward gear must turn freely on the input shaft.
If the clutches do not work correctly, disassemble the
clutches to find the problem.
RCPH10TLB054GAL 31
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33. Carry out the end float-check procedure of the clutch

pack on the both sides of the FWD-RVS GEAR
CLUTCH. In order to eliminate the end float position
the shaft on a suitable support(s) and apply a load
on the clutch counterdisk surface with a suitable
driver, as indicated in figure.
RCPH10TLB149ACL 32
34. In order to verify the end float feed the piston cham-
ber with compressed air at 6 bar (87.0 psi) and check
with a dial gauge located as shown in the photo the
real stroke “X”. Measure the end float X (see next
figure and figure 33 )
RCPH10TLB150ACL 33
35. Check the stroke of the piston. The end float value
must be: X= 1.60÷2.45 mm If the distance is not
within the range specified the clutch could be assem-
bled wrongly. Turn the clutch and repeat the same
operation for the other clutch pack (steps 33, 34 and
35).
RCPH10TLB004BAN 34
36. Assemble D shaft bearing using a suitable driver.
RCPH10TLB125ACL 35
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37. Assemble the input shaft (1). Assemble the idler

shaft (2).
RCPH10TLB177ACL 36
38. The operation is correct only if the two shafts are

fitted at the same time.
RCPH10TLB136ACL 37
Next operation:
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Shafts B- C
1. Use approved lifting equipment to begin lifting the
secondary shaft while you use your hands to lift the
primary shaft. At the same time, move the primary
shaft back and forth to keep the primary shaft moving
freely. It can be necessary to tap the ends of the
shift rods (from below the rear housing) so that the
shift rod and fork assemblies continue to move freely.
When the primary shaft is free of the rear housing
and the secondary shaft, remove the primary shaft.
RCPH10TLB913AAL 1
2. Remove the shift rod and fork assembly.
RCPH10TLB915AAL 2
3. Remove bearing by means of an extractor.
RCPH10TLB113AAL 3
4. Remove thrust washer and third speed gear.
RCPH10TLB779AAL 4
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RCPH10TLB172AAL 5
RCPH10TLB173AAL 6
NOTE: Take care during removal of sleeve, this will free the spring plates, hub pins and hub springs.
7. Remove the gear and clutch from the shaft.
RCPH10TLB174AAL 7
RCPH10TLB284AAL 8
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9. This figure shows the relationship between the plates

(1), the balls (2), the hub springs (3), and the syn-
chronizer hub (4). The synchronizer hub contains 3
plates,3 pins, and 3 springs.
RCPH10TLB076ACL 9
10. Remove fourth speed gear.
RCPH10TLB288AAL 10
RCPH10TLB184AAL 11
12. Remove the inner race bearing with a suitable ex-

tractor.
RCPH10TLB098ACL 12
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RCPH10TLB785AAL 13
14. Remove the shims (1)and the thrust washer (2).
RCPH10TLB137ACL 14
RCPH10TLB187AAL 15
16. Remove second speed gear.
RCPH10TLB193AAL 16
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17. Remove the first/second speed synchronizer assem-

bly.
RCPH10TLB101ACL 17
18. Remove synchronizer ring.
RCPH10TLB051ACL 18
19. Remove the steel ring (1)and the ring (2)together.
RCPH10TLB052ACL 19
20. Remove the tapered friction ring (1).
RCPH10TLB053ACL 20
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21. Turn the synchronizer assembly over and remove the

synchronizer ring (1)from the other side.
RCPH10TLB054ACL 21
22. Remove the steel ring (1)and the sintered ring (2).
RCPH10TLB055ACL 22
23. Remove the tapered friction ring (1).
RCPH10TLB056ACL 23
24. Support the sleeve on blocks. Push down on the hub

while you use a punch to push the detent assemblies
out of the sleeve and hub. Remove the sleeve from
the hub.
RCPH10TLB079ACL 24
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25. This photo shows the relationship between the balls,

the plate, the spring, and the hub.
RCPH10TLB079ACL 25
26. Remove first speed gear.
RCPH10TLB102ACL 26
RCPH10TLB103ACL 27
28. Remove the 4WD gear.
RCPH10TLB104ACL 28
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RCPH10TLB105ACL 29
30. Remove the inner race bearing (1)with an extractor.
RCPH10TLB080ACL 30
31. Turn the shaft. Remove bearing.
Next operation:
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Shaft assemblies - Assemble - S-Type (SPS Power Synchro) -

Shafts B- C
1. Put the secondary shaft on the bench so that the first-
second gear end is up. You can use a vise with soft
jaws to hold the secondary shaft in position. Install
the snap ring as shown.
RCPH10TLB105ACL 1
2. Assemble 4WD gear.
RCPH10TLB104ACL 2
3. Assemble the snap ring.
RCPH10TLB103ACL 3
4. Assemble the first speed gear.
RCPH10TLB102ACL 4
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5. Assemble the first/second speed synchronizer. This

photo shows the correct positions of the hub, the
sleeve, the springs, the plates, and the balls prior to
final assembly. The springs are installed in the hub,
and the plates are on the springs. The plates are not
yet pushed down into the sleeve and are holding the
hub up out of the sleeve. The balls are loose in the
recesses of the plates.
RCPH10TLB951AAL 5
6. Use a punch or screwdriver to push the balls into the

plates and to push the plates down so that the balls
are on the flat faces of the teeth, but not into the
detent grooves. When all the balls are in position,
push the hub and the plates down until the balls move
into the detent groove.
RCPH10TLB952AAL 6
7. Install the tapered friction ring on the synchronizer

assembly.
RCPH10TLB056ACL 7
8. Use clean transmission oil to lubricate the sintered

ring and the steel ring. Install the sintered ring and
the steel ring as shown in figure.
RCPH10TLB946AAL 8
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9. Install the synchronizer ring as shown in figure. The

flat sides of the teeth must be up.
RCPH10TLB945AAL 9
10. Turn the synchronizer assembly over and install the

tapered friction ring on the other side.
RCPH10TLB947AAL 10
11. Use clean transmission oil to lubricate the sintered

ring and the steel ring. Install the sintered ring and
the steel ring as shown. Install the top synchronizer
ring on the synchronizer assembly. Make sure that
the teeth on the top synchronizer ring are aligned with
the teeth on the inside of the sleeve. Push the sleeve
up until the sleeve engages the teeth on the top syn-
chronizer 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 completely engaged, the detent must hold the
sleeve in this position. Push the sleeve back down
to the neutral position, turn the synchronizer assem-
bly over, and repeat the procedure with the bottom RCPH10TLB946AAL 11
synchronizer ring. If the sleeve does not engage

the teeth smoothly or does not stay in position when
moved to any of the three positions, the synchronizer
assembly has damaged parts or was not assembled
correctly. Disassemble the synchronizer assembly to
find the problem.
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12. Install the top synchronizing ring (1)so that the flat
sides of the teeth are up. Install the first/second
speed synchronizer assembly (2).
RCPH10TLB101ACL 12
13. Assemble the second speed gear.
RCPH10TLB100ACL 13
14. Assemble roll pin.
RCPH10TLB099ACL 14
15. Assemble thrust washer (1)and shims (2).
RCPH10TLB107ACL 15
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16. Assemble snap ring. Measure the backlash X be-

tween gear and thrust washer: the value must be
between 0.2 -0.42 mm.
RCPH10TLB081ACL 16
17. Use a thickness gauge.
RCPH10TLB108ACL 17
18. If backlash X is more than the value prescribed re-

move the snap ring and the washer from their seat
and, using the shims shown in the chart reach the
prescribed value. Assemble shims between thrust
washer and snap ring.
RCPH10TLB137ACL 18
19. Heat the inner race of the bearing (1)to 80 - 100 °C

(176.0 - 212.0 °F). Assemble the inner race of the
bearing (1).Use a suitable driver.
RCPH10TLB082ACL 19
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20. Assemble the outer race bearing.
RCPH10TLB097ACL 20
21. Turn the shaft. Assemble the fourth speed gear.
RCPH10TLB135ACL 21
22. Assemble the third/fourth speed synchronizer This

figure shows the correct positions of the hub (1), the
sleeve (2), the springs (3), the plates (4), and the
balls (5)prior to final assembly. The springs are in-
stalled in the hub, and the plates are on the springs.
The plates are not yet pushed down into the sleeve
and are holding the hub up out of the sleeve. The
pins are loose in the recesses of the plates.
RCPH10TLB077ACL 22
23. Install the 3 sets of hub springs, hub pins and spring
plates into the synchronizer hub. Use a punch or
screwdriver to push the spring plates as the synchro-
nizer hub is installed into the sleeve. Be sure that
the spring plates are aligned with the grooves in the
sleeve.
RCPH10TLB952AAL 23
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24. Install the tapered friction ring on each side the syn-
chronizer assembly.
RCPH10TLB083ACL 24
25. Use clean transmission oil to lubricate and install the

clutch ring on each side of the synchronizer assem-
bly. Install the top synchronizer ring on the synchro-
nizer assembly. Make sure that the teeth on the top
synchronizer ring are aligned with the teeth on the
inside of the sleeve. Push the sleeve up until the
sleeve engages the teeth on the top synchronizer
ring. To do this, you must use enough force to over-
come the strength of the detent springs and balls.
When the synchronizer ring and the sleeve are com-
pletely engaged, the detent must hold the sleeve in
this position. Push the sleeve back down to the neu-
tral position, turn the synchronizer assembly over,
and repeat the procedure with the bottom synchro- RCPH10TLB134ACL 25
nizer ring. If the sleeve does not engage the teeth

smoothly or does not stay in position when moved to
any of the three positions, the synchronizer assembly
has damaged parts or was not assembled correctly.
Disassemble the synchronizer assembly to find the
problem.
26. Install the third/fourth speed synchronizer assembly
onto the shaft.
RCPH10TLB106ACL 26
47365539 08/07/2012
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washer. Assemble third speed gear and the thrust
washer onto the shaft.
RCPH10TLB084ACL 27
28. Heat the bearing (1)to 80 - 100 °C (176.0 - 212.0 °F).

Assemble bearing (1). Use a suitable driver.
RCPH10TLB085ACL 28
29. Heat the inner race of the bearing (1)to 80 - 100 °C

(176.0 - 212.0 °F). Assemble the inner race of the
bearing. Use a suitable driver.
RCPH10TLB086ACL 29
30. Turn the shaft. Heat the bearing to 80 - 100 °C (176.0

- 212.0 °F). Assemble bearing. Use a suitable driver.
RCPH10TLB088ACL 30
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31. Fit the pre assembled forks 3rd and 4th speed and
1st and 2nd as shown in the photo.
RCPH10TLB163ACL 31
32. Assemble the 4WD shaft Remove the secondary

shaft and the primary shaft. Use suitable lifting
apparatus.
RCPH10TLB178ACL 32
33. Position the group with care paying attention to the

location of fork pins in their seats.
RCPH10TLB164ACL 33
Next operation:
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Shaft E (4WD)
1. Remove shaft E.
RCPH10TLB719AAL 1
2. Remove the four-wheel drive clutch gear.
RCPH10TLB733AAL 2
NOTE: Make a mark on the top end of the reverse shaft so that you can install the reverse shaft with the same end
up during Assembly.
3. Remove bearing.
RCPH10TLB917AAL 3
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RCPH10TLB188AAL 4
5. Remove sleeve.
RCPH10TLB889AAL 5
6. Remove the two O-rings and sealing rings from the

shaft.
RCPH10TLB890AAL 6
7. Remove the four-wheel drive clutch tube (7) from the

front housing only if the front housing must be re-
placed or if the tube is leaking or damaged.
RCPH10TLB027ABL 7
Next operation:
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Shaft assemblies - Assemble - S-Type (SPS Power Synchro) - Shaft

E (4WD)
1. Assemble the O-Rings on the shaft. Lubricate with
oil transmission.
RCPH10TLB090ACL 1
2. Assemble sleeve.
RCPH10TLB129ACL 2
3. Assemble springs.
RCPH10TLB128ACL 3
4. Install spacer.
RCPH10TLB127ACL 4
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5. Position washer (1)and snap ring (2).
RCPH10TLB092ACL 5
6. Use a suitable tool to press the springs retainer down

until you have access to the snap ring. Install the
snap ring in the groove. Release the tension and
remove the tool. Make sure that the snap ring is
seated in the recess in the spring retainer.
RCPH10TLB091ACL 6
7. Place the protector 380001430 onto the shaft. The

expander/protector will stop in the correct position to
install the teflon sealing ring in the groove. Heat the
teflon sealing ring to 60 - 80 °C (140.0 - 176.0 °F)
Install it onto the expander/protector.
RCPH10TLB093ACL 7

RCPH10TLB094ACL 8
47365539 08/07/2012
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RCPH10TLB095ACL 9
from the shaft.
RCPH10TLB095ACL 10
11. Assemble protector 380001933. Repeat the opera-

tions from sequence 7 to sequence 10 for the intro-
duction of the second teflon ring. Lubricate the seals
with oil transmission.
RCPH10TLB096ACL 11
12. Apply air compressed at about 6 bar (87.0 psi)to

4WD clutch oil passage (see arrow) by plugging the
opposite hole with a finger. The sleeve should be
moving when compressing the springs . The 4WD
gear should move freely on 4WD shaft. If the opera-
tion is incorrect, dismantle to find the problem.
RCPH10TLB164GAL 12
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13. Install bearing.
RCPH10TLB124ACL 13
14. Install gear.
RCPH10TLB123ACL 14
15. Assemble shafts B and C. Assemble shaft E.
RCPH10TLB122ACL 15
16. If the four-wheel drive clutch tube (1)was removed

from the front housing, install the four-wheel drive
clutch tube. Torque wrench setting Powershift
transmission - Torque (21.113). Assemble the
front half housing on the rear half housing
RCPH10TLB130ACL 16
Next operation:
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Shaft assemblies - Disassemble - S-Type (SPS Power Synchro)

- Shift rails - forks
1. Remove the secondary shaft and the primary shaft .
Use suitable lifting device.
RCPH10TLB178ACL 1
2. Remove shift forks 1st and 2nd gear (1)and shift rail
(2).
RCPH10TLB143ACL 2
3. Remove shift forks 3rd and 4th gear (1)and shift rail
(2).
RCPH10TLB142ACL 3
4. If disassembly is required, remove the spring pins

(1)and separate the shift forks from the shift rails.
Make sure that you remember how the parts are as-
sembled and which parts go together. Inspect all
parts for burrs and excessive wear.
RCPH10TLB198ACL 4
Next operation:
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Shaft assemblies - Assemble - S-Type (SPS Power Synchro) - Shift

rails - forks
1. Pay attention to the proper forks assembly on the
shift rails holes. The shift rails are equal
RCPH10TLB141ACL 1
2. Assemble shift forks 1st and 2nd gear (1)onto the

shift rail (2). Dimension A: about 46 mm
RCPH10TLB073ACL 2
3. Assemble shift forks 3rd and 4th gear (1)onto the shift
rail (2). Dimension B: about 62 mm
RCPH10TLB074ACL 3
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4. Pay attention to the proper assembly
RCPH10TLB075ACL 4
5. Position the roll pin.
RCPH10TLB198ACL 5
6. 1st and 2nd gear shift fork. Assemble the spring pin
to lock the fork to the shift rail.
RCPH10TLB071ACL 6
7. 3rd and 4th gear shift fork. Assemble the spring pin
to lock the fork to the shift rail.
RCPH10TLB072ACL 7
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8. Assemble shift forks 3rd and 4th gear and shift rail
on the synchronizer.
RCPH10TLB142ACL 8
9. Assemble shift forks 1st and 2nd gear and shift rail
on the synchronizer.
RCPH10TLB143ACL 9
10. Assemble the 4WD shaft on the rear half-housing.

Assemble the secondary shaft and the primary shaft.
Use suitable lifting equipment.
RCPH10TLB178ACL 10
11. Position the group with care paying attention to the

location of fork pins in their seats.
RCPH10TLB164ACL 11
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Clutch - Measure - S-Type (SPS Power Syncro) - Speed gears shift

rails adjustment - Back side measurement
1. Operate on the front side. Remove the screw and
the front engagement bushing with shims.
RCPH10TLB213ACL 1
2. Assemble the dealer made tool for the load applica-

tion.
RCPH10TLB242ACL 2
3. Pull the dealer made tool in order to apply a 2 kg (4.5

lb) load.
RCPH10TLB241ACL 3
4. Control and note the calibrated length A of the dealer

made tool (calibrated length A= 115 mm (4.5 in)).
RCPH10TLB263ACL 4
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5. Operate on the rear side. Assemble the tool and use

it as a guide for the special tool.
RCPH10TLB258ACL 5
6. Assemble the tool.
RCPH10TLB259ACL 6
7. Assemble the tool.
RCPH10TLB260ACL 7
8. Assemble the tool for the splined shaft blocking.
RCPH10TLB261ACL 8
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9. Measure the distance from the tool shoulder to the

upper shaft end by using a depth gauge. Note the
measured value M(R)
RCPH10TLB262ACL 9
10. Calculate the dimension C value: C= M(R)- A [ m m ]
RCPH10TLB026ACL 10
11. Measure the rear engagement bushing outer length

and note the measured value LE(R).
RCPH10TLB264ACL 11
12. Measure the rear engagement bushing depth and

note the measured value LI(R).
RCPH10TLB265ACL 12
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13. Calculate total shim SR value for the rear engage-

ment bushing: S(R)= C - (LE(R)- LI(R)) [ m m ]
RCPH10TLB016ACL 13
14. Operate on the rear side. Remove the tool and as-
semble the tool to the upper shaft. Assemble the
shims by using the tool as a guide.
RCPH10TLB266ACL 14
15. Assemble the rear engagement bushing by using the

special tool as a guide, in order to assemble the
shims too.
RCPH10TLB268ACL 15
NOTE: The bushing external slots must be positioned as shown in figure.

16. Shaft-bushing coupling: the bushing rotation stop
tooth must be coupled with the slot on the upper
shaft.
RCPH10TLB025ACL 16
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17. Operate on the front side. Remove the tool for the
load application. Operate on the rear side. Assemble
the tool to the upper shaft.
RCPH10TLB243ACL 17
Next operation:
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rails adjustment - Front side measurement
1. Operate on the front side. Assemble the special tool
and use it as a guide for the special tool . Assemble
the special tool . Assemble the special tool.
RCPH10TLB210ACL 1
2. Operate on the rear side. Pull the special tool in order

to apply a 2 kg load to the upper shaft.
RCPH10TLB243ACL 2
3. Operate on the front side. Measure the distance from

the special tool shoulder to the upper shaft end by
using a depth gauge. Note the measured value M(F).
RCPH10TLB210ACL 3
4. Calculate the dimension B value: B= M(F)- A [ m m

] Where A is the calibrated length on the special tool
(calibrated length A= 115 mm)
RCPH10TLB027ACL 4
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5. Measure the front engagement bushing outer length

and note the measured value LE(F).
RCPH10TLB264ACL 5
6. Measure the front engagement bushing depth and

note the measured value LI(F).
RCPH10TLB265ACL 6
7. Calculate total shim SF value for the rear engage-

ment bushing: SF= C - ( LE(F)- LI(F)) [mm]
RCPH10TLB016ACL 7
8. Operate on the front side. Remove the special tool

and assemble the special tool to the upper shaft.
Assemble the shims by using the special tool as a
guide.
RCPH10TLB211ACL 8
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9. Assemble the front engagement bushing by using

the special tool as a guide, in order to assemble the
shims too.
RCPH10TLB212ACL 9
NOTE: The bushing external slots must be positioned as shown

10. Remove the special tool . Assemble the bushing
fastening screw.
RCPH10TLB213ACL 10
11. Tighten the bushing fastening screw to the requested

torque Powershift transmission - Torque (21.113).
RCPH10TLB214ACL 11
Next operation:
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rails adjustment - Dimension "D" measurement
1. Operate on the rear side. Push the special tool (t1)
in order to apply a 2 kg load as shown in figure.
RCPH10TLB244ACL 1
2. Operate on the front side. Measure the distance D(1)

from the ledge to the upper shaft end by using a
depth gauge. Note the measured value D(1).
RCPH10TLB215ACL 2
3. Measure the depth D(2) from the ledge to the pistons

seat end by using a depth gauge. Note the measured
value D(2).
RCPH10TLB028ACL 3
4. D(2) measurement.
RCPH10TLB216ACL 4
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5. Calculate and note the dimension D value: D = D(2)-

D(1) [ m m ]
RCPH10TLB029ACL 5
Next operation:
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rails adjustment - Neutral position measurement
1. Remove the bolt from the front piston.
RCPH10TLB219ACL 1
2. Control and note the front piston length P (P= 19 mm)
RCPH10TLB247ACL 2
3. Measure and note the screw head height T.
RCPH10TLB247ACL 3
4. Operate on the front side. Measure and note the

depth D(1) from the ledge to the first shoulder into
the upper shaft pistons seat.
RCPH10TLB218ACL 4
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5. Measure and note the depth D(3). Calculate the

depth D(4): D(4)= D(2)- D(3) [ mm]
RCPH10TLB030ACL 5
6. - D4 is the dimension calculated in the previous step;

- D is the dimension calculated in the previous para-
graph.
RCPH10TLB031ACL 6
7. Calculate the value of the total shim S(V) that have to

be positioned under the screw (8) head: S(V)= D(4)-
(D/2) - P -T [ mm ]
RCPH10TLB032ACL 7
8. Assemble the screw and the shims to the front piston.
RCPH10TLB245ACL 8
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9. Stop the piston with a suitable open-end wrench then

tighten the screw to the requested torque.
RCPH10TLB219ACL 9
10. Verify the indicated distance: P+S(V)+ T [ mm ]
RCPH10TLB248ACL 10
11. Operate on the rear side. Engage the “neutral” posi-

tion by using the special tool.
RCPH10TLB243ACL 11
12. Remove the special tool. Assemble the bushing fas-

tening screw to the shift rail.
RCPH10TLB208ACL 12
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13. Tighten the rear bushing fastening screw to the re-

quested torque.
RCPH10TLB209ACL 13
14. Assemble the pistons.
RCPH10TLB015ACL 14
15. Proceed with the speed gear switches check proce-

dure.
RCPH10TLB033ACL 15
Next operation:
Clutch - Check (21.155)
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Clutch - Check - S-Type (SPS Power Syncro) - Speed gears switches

- Checking procedure
1. Fabricate a tool, composed of threaded tie-rod, nut,
the spacer tee-handle.
RCPH10TLB109ACL 1
2. On the backside of the transmission, Install the

dealer made tools as shown in figure 2.
RCPH10TLB220ACL 2
3. If not assembled, insert the switch detents and the

relative springs into the gear switches holes.
RCPH10TLB221ACL 3
4. If not assembled, assemble the gear switches.
RCPH10TLB222ACL 4
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5. Assemble the upper gear switches. (3rd) 3rd gear

switch; (4th) 4th gear switch; and the lower: (1st) 1st
gear switch; (2nd) 2nd gear switch.
RCPH10TLB151ACL 5
6. Tighten the switches to the specified torque Power-

shift transmission - Torque (21.113).
RCPH10TLB223ACL 6
7. To tighten the 2nd and 4th gear switch, use a wrench.
RCPH10TLB224ACL 7
8. Prepare the data control electronic box for the

switches regulation: the electronic box must be sim-
ilar to the one schematic shown in figure 8. The box
must have four pilot light, each one corresponding
to a different engagement switch, that light when the
gear is engaged (in figure the pilot lights are marked
with “SW” followed by the gear number). The simul-
taneous lighting of two pilot lights corresponding to
switches installed on the same shaft, correspond to
the neutral gear engagement (in figure the neutral
position is marked with “N”).
RCPH10TLB018ACL 8
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9. Connect the switches cables to data control the elec-

tronic box.
RCPH10TLB225ACL 9
10. Connect the switches cables as shown in figure: A

- 3rd gear switch; B - 4th gear switch; C - 1st gear
switch; D - 2nd gear switch.
RCPH10TLB024ACL 10
11. Operate on the front side. Remove the screw from

bushing.
RCPH10TLB213ACL 11
NOTE: The gear switches check procedure starts with the switches assembled on the upper shaft (3rd and 4th gear
switches).
12. Assemble the dealer made tool to the upper shaft, by
screwing it to the shaft.
RCPH10TLB232ACL 12
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13. Push the dealer made tool until the end of stroke,
in order to engage the third gear. Fix the spacer on
the special tool to the transmission by using two M8
screws.
RCPH10TLB226ACL 13
14. Operate on the back side. Assemble a comparator

for linear measurement and position the comparator
stylus tip on contact with the upper shaft end.
RCPH10TLB227ACL 14
15. Positioning of the stylus tip on contact with the upper

shaft.
RCPH10TLB227ACL 15
16. It is possible to make the measurements with a depth

gauge instead of the comparator.
RCPH10TLB231ACL 16
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17. In the actual assembly position, on the electronic

box, must be lighted the pilot light corresponding to
the third gear engagement.
RCPH10TLB229ACL 17
NOTE: Set the comparator to zero.

18. Operate on the front side. Proceed to the switches
check for the FORWARD STROKE as indicated on
the following steps, by regulating the upper shaft po-
sition with the regulation nut installed on the dealer
made tool. Turn the nut in order to move the upper
shaft toward the fourth gear engagement (front side).
RCPH10TLB230ACL 18
19. During the checking procedure compile the check ta-

ble and compare the measured values with the refer-
ence ones. Insert the measured values on the “MEA-
SURED VALUE” column.
RCPH10TLB019ACL 19
20. The actual position (third gear engaged at end of the

stroke and SW3 light switched to ON) corresponds
to the “zero” position and is indicated in table with “0”
(THIRD GEAR ENGAGED).
RCPH10TLB020ACL 20
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NOTE: Reminder: The procedure starts with the upper shaft switch check (third and fourth gear), so the involved pilot
lights are the ones relative to SW3 and SW4 switches.
21. Operate slowly on the regulation nut as shown in step
[19], until the SW3 pilot light turns to OFF. Note on the
table the value measured by the comparator (THIRD
GEAR - MEASURE 1)
RCPH10TLB230ACL 21
22. Electronic box status in the current position.
RCPH10TLB018ACL 22
23. Operate slowly on the regulation nut, until the SW4

pilot light turns to ON. Note on the table the value
measured by the comparator (NEUTRAL POSITION
- MEASURE 2).
RCPH10TLB230ACL 23
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RCPH10TLB022ACL 24

- MEASURE 3).
RCPH10TLB230ACL 25
26. Electronic box status in the current position (neutral

position).
RCPH10TLB021ACL 26
27. Operate slowly on the regulation nut until the SW4

pilot light turns to OFF. Note on the table the value
- MEASURE 4).
RCPH10TLB230ACL 27
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RCPH10TLB020ACL 28
29. Operate slowly on the regulation nut until the SW3

pilot light turns to OFF. Note on the table the value
- MEASURE 5).
RCPH10TLB230ACL 29
RCPH10TLB018ACL 30

measured by the comparator (FOURTH GEAR -
MEASURE 6).
RCPH10TLB230ACL 31
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RCPH10TLB022ACL 32
33. Operate slowly on the regulation nut, until the end of

the stroke and note on the table the value measured
by the comparator (FOURTH GEAR - MEASURE 7)
RCPH10TLB230ACL 33
RCPH10TLB022ACL 34
35. Operate on the front side. Proceed to the switches

check for the BACKWARD STROKE by carrying out
backwards the steps from [21] to [34] and note the
measured values on the check table. Turn the nut in
order to move the upper shaft toward the third gear
engagement (back side).
RCPH10TLB230ACL 35
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36. Proceed with the lower shaft switches check (first

and second gear). Repeat the operations from step
[12] to step [34], where it must be used SW1 instead
of SW3 and SW2 instead of SW4. Carry out the
same measure by using the linear comparator and
note the values in the relative column on the checking
table.
RCPH10TLB230ACL 36
37. Compare the measured values obtained from the

procedure with the reference values.
RCPH10TLB023ACL 37
38. If the check results are not positive, adjust the shims
to obtain the prescribed tolerance range. Carry out
the switches check procedure again.
RCPH10TLB017ACL 38
Third and fourth gear check list

Stroke Gear Measure SW3 SW4 Measured Reference Result
Value (mm) Value (mm)
- ON OFF 0 Engaged
3rd
1 OFF OFF 0.6/1.5
2 OFF ON OFF ON
7.6/8.8
3 OFF ON OFF ON
Forward Neutral
4 OFF ON OFF ON
11.4/12.6
5 OFF OFF
6 OFF ON 18.7/19.6
4th
7 OFF ON End of stroke
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Third and fourth gear check list

- OFF ON Engaged
4th
1 OFF OFF 0.6/1.5
2 OFF ON OFF ON
7.6/8.8
3 OFF ON OFF ON
Backward Neutral
4 OFF ON OFF ON
11.4/12.6
5 OFF OFF
3rd 6 ON OFF 18.7/19.6
7 ON OFF End of stroke
First and second gear check list

Stroke Gear Measure SW1 SW2 Measured Reference Result
Value (mm) Value (mm)
- ON OFF 0 Engaged
1st
1 OFF OFF 0.6/1.5
2 OFF ON OFF ON
8.1/9.3
3 OFF ON OFF ON
Forward Neutral
4 OFF ON OFF ON
11.8/13.0
5 OFF OFF
6 OFF ON 19.6/20.5
2nd
7 OFF ON End of stroke
- OFF ON Engaged
2nd
1 OFF OFF 0.6/1.5
2 OFF ON OFF ON
8.1/9.3
3 OFF ON OFF ON
Backward Neutral
4 OFF ON OFF ON
11.8/13.0
5 OFF OFF
1st 6 ON OFF 19.6/20.5
7 ON OFF End of stroke
Next operation:
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Index
Transmission - 21

Clutch - Check - S-Type (SPS Power Syncro) - Speed gears switches - Checking procedure . . . . . . . . . . . . . . . . 95
Clutch - Exploded view - H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch - Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Back side measurement 81
Clutch - Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Dimension "D" measurement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Clutch - Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Front side measurement 86
Clutch - Measure - S-Type (SPS Power Syncro) - Speed gears shift rails adjustment - Neutral position measurement
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Shaft assemblies - Assemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Shaft assemblies - Assemble -S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . . . 12
Shaft assemblies - Assemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Shaft assemblies - Assemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Shaft assemblies - Assemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Shaft assemblies - Assemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Shaft assemblies - Disassemble -S-Type (SPS Power Synchro) - Gear pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Shaft assemblies - Disassemble - S-Type (SPS Power Synchro) - Rear cover - shafts . . . . . . . . . . . . . . . . . . . . . . . 8
Shaft assemblies - Disassemble - S-Type (SPS Power Synchro) - Shaft E (4WD) . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Shaft assemblies - Disassemble - S-Type (SPS Power Synchro) - Shafts A - D . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Shaft assemblies - Disassemble - S-Type (SPS Power Synchro) - Shafts B- C . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Shaft assemblies - Disassemble - S-Type (SPS Power Synchro) - Shift rails - forks . . . . . . . . . . . . . . . . . . . . . . . . 76
Shaft assemblies - Exploded view - H-Type - Reverse shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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PRINTED IN U.S.A.
47365539 08/07/2012
EN
SERVICE MANUAL
Front axle system
580N
580SN WT
580SN
590SN
47365539 08/07/2012
25
Contents
Front axle system - 25
Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.100

580N , 580SN WT , 580SN , 590SN
Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.102

580N , 580SN WT , 580SN , 590SN
Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.108

580N , 580SN WT , 580SN , 590SN
Non-powered front axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.400

580N , 580SN WT , 580SN , 590SN
47365539 08/07/2012
25
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 270 Front axle - Assemble - Carraro Front axle two wheel drive 25.400 / 18
Loctite® 270 Front axle - Assemble - CNH Front Axle - Two Wheel Drive 25.400 / 28
47365539 08/07/2012
25
47365539 08/07/2012
25
Powered front axle - 100
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
Four-Wheel drive (4WD) axle

General specification - CNH Front Axle Four Wheel Drive - 580N and 580SN . . . . . . . . . . . . . . . . . . . . . . 4
580N, 580SN
General specification - CNH Front Axle Four Wheel Drive - 580SN-WT and 590SN . . . . . . . . . . . . . . . . . 4
580SN WT NA, 590SN
Special tools - CNH Front Axle Four Wheel Drive - 580N, 580SN, 580SN-WT, 590SN . . . . . . . . . . . . . . . 5
580N, 580SN, 580SN WT NA, 590SN
General specification - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . 11
580N, 580SN
Special tools - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . 11
580N, 580SN
General specification - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . 14
580SN WT NA, 590SN
Special tools - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . 15
580SN WT NA, 590SN
FUNCTIONAL DATA

Exploded view - CNH Four wheel drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Drawing - Front axle-four wheel drive- measuring toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Axle housing
Exploded view - Carraro Front axle- swivel housing- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Exploded view - CNH Front axle - swivel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SERVICE

Remove - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
580N, 580SN, 580SN WT NA, 590SN
Install - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

580N, 580SN, 580SN WT NA, 590SN
Axle housing
Disassemble - CNH Front Axle -Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assemble - CNH Front Axle- Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Disassemble - Carraro Front axle-four wheel drive swivel housing and universal joint- 580N and 580SN
only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
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Assemble - Carraro Front axle-four wheel drive swivel housing and universal joint- 580N and 580SN only
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Disassemble - Carraro Front axle-four wheel drive swivel housing- 580SN-WT and 590SN only . . . . . 54
Assemble - Carraro Front axle-four wheel drive swivel housing- 580SN-WT and 590SN only . . . . . . . . 64
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Front axle system - Powered front axle
Four-Wheel drive (4WD) axle - General specification - CNH Front

Axle Four Wheel Drive - 580N and 580SN
580N, 580SN
Specifications
Tie rod length securing nut 111 - 137 N·m (81.9 - 101.0 lb ft)
Tie rod ball joint nut 129 - 160 N·m (95.1 - 118.0 lb ft)
Tie rod ball joint 255 - 315 N·m (188.1 - 232.3 lb ft)
Breather 11 - 14 N·m (8.1 - 10.3 lb ft)
Beam drain plug/fill 54 - 66 N·m (39.8 - 48.7 lb ft)
Lube fitting, king pin 25 - 35 N·m (18.4 - 25.8 lb ft)
Planet carrier retention screw 21 - 26 N·m (15.5 - 19.2 lb ft)
King pin bolt 154 - 188 N·m (113.6 - 138.7 lb ft)
Differential cover bolt 96 - 118 N·m (70.8 - 87.0 lb ft)
Steering cylinder bolt 358 - 442 N·m (264.0 - 326.0 lb ft)
Steering stop nut 200 - 244 N·m (147.5 - 180.0 lb ft)
Sun shaft retention nut 358 - 442 N·m (264.0 - 326.0 lb ft)
Ring gear support bolt 55 - 68 N·m (40.6 - 50.2 lb ft)
Planet pin screw 95 - 105 N·m (70.1 - 77.4 lb ft)
Planetary drain plug 72 - 88 N·m (53.1 - 64.9 lb ft)
Bearing cap bolt 96 - 118 N·m (70.8 - 87.0 lb ft)
Ring nut retainer bolt 21 - 26 N·m (15.5 - 19.2 lb ft)
Bevel crown bolt 96 - 118 N·m (70.8 - 87.0 lb ft)
Pinion shaft bearing rolling torque 1.7 - 2.2 N·m (1.3 - 1.6 lb ft)
Differential bearing rolling torque 1.5 - 2.5 N·m (1.1 - 1.8 lb ft)
Wheel bearing with seal rolling torque 8 - 30 N·m (5.9 - 22.1 lb ft)
Open differential rolling torque (Internal diff gears) 0 - 1 N·m (0.0 - 0.7 lb ft)
Limited slip differential rolling torque (Internal diff gears) 1 - 5 N·m (0.7 - 3.7 lb ft)
Capacities
Differential 7.7 l (8.1 US qt) or bottom of fill hole.
Planetary 0.5 l (0.5 US qt) or fill to line.
Type of Fluid Wet Brake/Transmission Lubricant - SAE 80W140
(MAT3510)
Lubricant Kluberplus 84279121
NOTE: All new or used hardware should have Loctite 242 applied prior to installation. The manufacturer recommends
replacement of all hardware to include O-rings.
Four-Wheel drive (4WD) axle - General specification - CNH Front

Axle Four Wheel Drive - 580SN-WT and 590SN
580SN WT NA, 590SN
Specifications
Breather 11 - 14 N·m (8.1 - 10.3 lb ft)
Beam drain plug/fill 54 - 66 N·m (39.8 - 48.7 lb ft)
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Specifications
Planetary drain plug 72 - 88 N·m (53.1 - 64.9 lb ft)
Pinion shaft bearing rolling torque 1.7 - 2.2 N·m (1.3 - 1.6 lb ft)
Differential bearing rolling torque 1.5 - 2.5 N·m (1.1 - 1.8 lb ft)
Wheel bearing with seal rolling torque 12 - 25 N·m (8.9 - 18.4 lb ft)
Open differential rolling torque (Internal diff gears) 0 - 1 N·m (0.0 - 0.7 lb ft)
Limited slip differential rolling torque (Internal diff gears) 1 - 5 N·m (0.7 - 3.7 lb ft)
Capacities
Axle
(MAT3510)
NOTE: All new or used hardware should have Loctite 242 applied prior to installation. The manufacturer recommends
replacement of all hardware to include O-rings.
Four-Wheel drive (4WD) axle - Special tools - CNH Front Axle Four
Wheel Drive - 580N, 580SN, 580SN-WT, 590SN
580N, 580SN, 580SN WT NA, 590SN
CAS1840C or DMT100002 Spanner Wrench
RCPH10TLB633ABL 1
Yoke to hold shaft
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RCPH10TLB638ABL 2
CAS-1980 V-Block. Used to support coupling when replacing a universal joint.
RCPH10TLB684ABL 3
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380100092 Wrench to loosen and tighten tie rods for steering cylinder.
RCPH10TLB235ABL 4
CAS2369 or 380100103- Seal protector
RCPH10TLB635ABL 5
DMT100001- Pinion Seal Installation Tool
RCPH10TLB025FAL 6
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DMT100002- Thrust Bearing Installation/Removal Tool
RCPH10TLB026FAL 7
DMT100003- Sun Shaft Seal Installation Tool
RCPH10TLB027FAL 8
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DMT100004- Hub Seal Installation Tool
RCPH10TLB033FAL 9
DMT100005- Axle Housing Shaft Bushing Installation Tool
RCPH10TLB029FAL 10
DMT100006- Axle Housing Shaft Seal Installation Tool
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RCPH10TLB030FAL 11
3800000468- Pinion Nut Wrench
RCPH10TLB261ACL 12
380100102- Pinion Shaft Wrench
RCPH10TLB260ACL 13
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Four-Wheel drive (4WD) axle - General specification - Carraro Front

axle-four wheel drive - 580N and 580SN only
580N, 580SN
General specifications
Backlash for ring gear 0.20 - 0.25 mm (0.008 - 0.010 in)
Rotating torque for pinion shaft without seal 1.1 - 2.3 N·m (9.74 - 20.36 lb in)
Lubricant 580N and 580SN

Capacity - center bowl 5.5 l (5.8 US qt)
Capacity - each wheel end 0.71 l (0.75 US qt)
Type of fluid Wet brake/Transmission lubricant - SAE 80W140
MAT3510
Special torques
Studs for wheels 70 N·m (51.6 lb ft)
Allen head bolts for carrier 25 N·m (18.4 lb ft)
Self locking nut for tie rod ball joint 165 N·m (121.7 lb ft)
Jam nut for tie rod 120 N·m (88.5 lb ft)
Nut for ball joint for steering cylinder 300 N·m (221.3 lb ft)
Bolts for steering cylinder 120 N·m (88.5 lb ft)
Jam nuts for steering stops 150 N·m (110.6 lb ft)
Bolts for king pin 120 N·m (88.5 lb ft)
Bolts for adjusting ring lock 13 N·m (115.1 lb in)
Bolts for bearing caps 266 N·m (196.2 lb ft)
Bolts for hub for planetary ring gear 95 N·m (70.1 lb ft)
Bolts for differential carrier 169 N·m (124.6 lb ft)
Oil drain plugs in axle housing 60 N·m (44.3 lb ft)
Oil drain plugs in planetary ends 80 N·m (59.0 lb ft)
Breather 10 N·m (88.5 lb in)
Grease zerks 8 N·m (70.8 lb in)
Wheel nuts 350 N·m (258.1 lb ft)
Four-Wheel drive (4WD) axle - Special tools - Carraro Front

axle-four wheel drive - 580N and 580SN only
580N, 580SN
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CAS 1839 Pinion setting kit

1. CAS1839-1 Gauge tube
RCPH10TLB461ABL 1
2. CAS1839-2 Gauge block

3. CAS1668 Metric feeler gauge
4. CAS2401 Pilot
5. CAS1596A-4 Handle
6. CAS1596A Stud
CAS1840C Spanner wrench
RCPH10TLB468ABL 2
CAS2151A Wrench for pinion nut
RCPH10TLB465ABL 3
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Yoke to hold shaft
RCPH10TLB467ABL 4
CAS1842 Wheel stud removal and installation
RCPH10TLB466ABL 5
CAS1980 V-Block used to support coupling when replac-

ing a universal joint
RCPH10TLB469ABL 6
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380100091 for all two wheel drive and the 580N, 580SN
four wheel drive front axle
RCPH10TLB235ABL 7
38010092 for the 580SN - WT and 590SN four wheel drive

front axle
CAS2369 - Seal protector
CAS2375 - Shaft adapter
CAS10468 - Puller
Four-Wheel drive (4WD) axle - General specification - Carraro Front

axle-four wheel drive - 580SN-WT and 590SN only
580SN WT NA, 590SN

Rotating torque for pinion shaft without seal 1.1 - 2.3 N·m (9.7 - 20.4 lb in)
Lubricant - 580SN
Type of fluid Wet brake/transmission lubricant - SAE 80W140
MAT3510
Lubricant - 590SN
Type of fluid Wet brake/transmission lubricant - SAE 80W140 MAT
3510
Special torques
Stud for wheels 70 N·m (51.6 lb ft)
Allen head bolts for carrier 25 N·m (18.4 lb ft)
Nut for ball joint for steering cylinder 300 N·m (221.3 lb ft)
Jam nuts for steering stops 150 N·m (110.6 lb ft)
Bolts for king pins 190 N·m (140.1 lb ft)
Bolts for adjusting ring lock 13 N·m (115.1 lb in)
Bolts for differential case 169 N·m (124.6 lb ft)
Bolts for differential carrier 169 N·m (124.6 lb ft)
Oil drain plugs in axle housing 60 N·m (44.3 lb ft)
Oil drain plugs in planetary ends 80 N·m (59.0 lb ft)
Breather 10 N·m (88.5 lb in)
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Special torques
Grease zerks 8 N·m (70.8 lb in)
Self locking nut for tie rod ball joint

580SN-WT 165 N·m (121.7 lb ft)
590SN 220 N·m (162.3 lb ft)
Jam nut for tie rod

580SN-WT 120 N·m (88.5 lb ft)
590SN 250 N·m (184.4 lb ft)
Bolts for hub for planetary ring gear

580SN-WT 95 N·m (70.1 lb ft)
590SN 120 N·m (88.5 lb ft)
Four-Wheel drive (4WD) axle - Special tools - Carraro Front

axle-four wheel drive - 580SN-WT and 590SN only
580SN WT NA, 590SN
CAS 1839 Pinion setting kit

1. CAS1839-1 Gauge tube
RCPH10TLB461ABL 1
2. CAS1839-2 Gauge block

3. CAS1668 Metric feeler gauge
4. CAS2401 Pilot
5. CAS1596A-4 Handle
6. CAS1596A Stud
CAS1840C Spanner wrench
RCPH10TLB633ABL 2
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CAS2151A Wrench for pinion nut
RCPH10TLB637ABL 3
Yoke to hold shaft
RCPH10TLB638ABL 4
CAS1842 Wheel stud removal and installation
RCPH10TLB683ABL 5
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CAS1980 V-Block used to support coupling when replac-

ing a universal joint
RCPH10TLB684ABL 6
38010092 Wrench to loosen and tighten tie rods for steer-

ing cylinder
RCPH10TLB235ABL 7
Seal driver 380002431
RCPH10TLB636ABL 8
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Seal protector CAS2369
RCPH10TLB635ABL 9
RCPH10TLB634ABL 10
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Four-Wheel drive (4WD) axle - Exploded view - CNH Four wheel

drive axle
RCPH10TLB388ACL 1
(1) Axle (7) Retainer

(2) Bolt (8) Bolt
(3) Snap ring (9) Bolt
(4) Spacer (10) Washer
(5) Pivot pin (11) Drive shaft guard
(6) Drive shaft
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Four-Wheel drive (4WD) axle - Drawing - Front axle-four wheel

drive- measuring toe-in
1. Mark around center of tire
2. Steering cylinder
3. Loosen the jam nut and turn the piston rod as required
4. Top axle measurement must be equal to or up to 5 mm (0.2 in) less than bottom axle measurement.
RCPH10TLB001FAL 1
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Axle housing - Exploded view - Carraro Front axle- swivel housing-

1. Bolt 4. Bushing 7. Swivel housing
2. Top king pin 5. Seal 8. Grease zerk
3. Belleville washer 6. Bushing 9. Bottom king pin
RCPH10TLB001GAL 1
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Axle housing - Exploded view - CNH Front axle - swivel housing

Swivel Housing
1. Bolt
2. Bottom king pin
3. Grease zirk
4. Bushing
5. Bellville washer
6. Swivel housing
7. Top king pin
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RCPH10TLB182GAL 1
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Four-Wheel drive (4WD) axle - Remove - Four wheel drive machines

580N, 580SN, 580SN WT NA, 590SN
Prior operation:
Prior operation:
Front wheels - Remove (44.511)
RCPH10TLB388ACL 1
1. Put a floor jack under the drive shaft guard (11) to

hold the drive shaft guard in position.
2. Loosen and remove the bolts (9) and flat washers
(10) that fasten the drive shaft guard (11) to the
frame.
3. Lower the drive shaft guard (11) and remove it from
under the machine.
4. Loosen and remove the bolts (8) and retainers (7)
that fasten the drive shaft (6) to the flange on the
transmission. Remove the drive shaft (6).
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5. Install blocks between the axle (1) stops and the

frame to prevent the axle from tilting.
RCPH11TLB136AAM 2
6. Identify, tag and disconnect the steering hoses. Cap

all open ports.
RCPH11TLB146AAM 3
7. Disconnect the lubrication hose from the axle (1).
RCPH11TLB139AAM 4
8. Put a floor jack under the axle (1) to hold the axle in
position.
RCPH11TLB140AAM 5
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9. Remove the snap ring (3) from the rear of the pivot
pin (5).
RCPH11TLB141AAM 6
10. Remove bolt (2) and install a slide hammer into the
pivot pin (5), pull the pivot pin (5) out of the frame.
RCPH11TLB143AAM 7
11. Washers are used at the front and rear of the axle
(1), between the axle and the frame. Lower the axle
(1) and remove the washers (4).
RCPH11TLB144AAM 8
12. Remove the axle (1) from under the machine.
RCPH11TLB145AAM 9
Next operation:
Powered front axle - Install (25.100)
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Four-Wheel drive (4WD) axle - Install - Four wheel drive machines

580N, 580SN, 580SN WT NA, 590SN
Prior operation:
Powered front axle - Remove (25.100)
1. Raise the axle (1) into alignment with the frame.
RCPH11TLB140AAM 1
2. Install the pivot pin (5) with the bolt hole end of the
pivot pin toward the front of the machine.
RCPH11TLB147AAM 2
3. Install a washer (4) between the front of the axle (1)

and the frame. Use washer(s) as required for mini-
mum end play between the frame and the axle (1).
4. Start the pivot pin (5) into the frame, washer (4), and
axle (1).
5. Drive the pivot pin (5) into the rear pivot of the axle
(1) but not through the rear pivot.
6. Install a washer (4) between the rear of the axle (1)
and the frame.
7. Drive the pivot pin (5) through the rear pivot and the
frame.
8. Install the snap ring (3) on the pivot pin (5).
9. Drive the pivot pin (5) toward the front of the machine
as far as possible.
10. Check the end play between the frame and the snap
ring (3) on the pivot pin (5) at the front of the machine.
Use washers (4) as required to remove any end play.
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11. Connect the lubrication hose to the axle (1).
RCPH11TLB139AAM 3
12. Loosen and remove the plugs from the hoses and the
caps from the fittings for the steering cylinder.
RCPH11TLB146AAM 4
13. Connect the hoses to the steering cylinder.

14. Install the wheels, hardened washers , and nuts.
15. Tighten the wheel nuts to 122 N·m (90 lb ft)+ 3 - 10
N·m (2 - 7 lb ft). Then turn nut an additional 90 ° ±
5 °.
16. Remove the blocks from between the axle (1) stops
and the frame.
17. Remove the stands and lower the wheels to the floor.
18. Lubricate the pivot pin (5) for the axle (1).
19. Install the drive shaft (6). Install the bolts (8) and re-
tainers (7) that fasten the drive shaft (6) to the flange
on the transmission.
20. Tighten the bolts to 33 - 39 N·m (24 - 29 lb ft).
21. Raise the drive shaft guard (11) in position.
NOTE: If your machine is equipped with a powershift trans-
mission, install O-ring and spacer on the bolts, use the
O-ring to hold the hardware in place.
22. Install the bolts (9) and flat washers (10) that fasten
the drive shaft guard (11) to the frame.
23. Torque the bolts (9) to 50 - 90 N·m (36.9 - 66.4 lb ft).
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Axle housing - Disassemble - CNH Front Axle -Four Wheel Drive

1. See housing exploded view: Axle housing - Ex-
ploded view (25.100)
NOTE: Steering stop screws are set per tires/loader combinations.

2. Do the necessary steps under disassembly of Plan-
etary Planetary drive and hub - Disassemble
(25.108) for access to the swivel housing.
3. Loosen the tie rod nut.
RCPH10TLB951ABL 1
4. Use a two jaw puller to loosen the ball joint. Remove

the tie rod nut and remove the ball joint from the
swivel housing. Remove the tie rod.
RCPH10TLB952ABL 2
NOTE: Remove and discard nut. DO NOT reuse.

5. Remove the nut and ball joint.
RCPH10TLB484ABL 3
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6. Fasten acceptable lifting equipment as shown.
RCPH10TLB390ACL 4
7. Remove the bolts (3)and use acceptable tools to re-

move the top king pin.
RCPH10TLB391ACL 5
8. Remove top king pin.
RCPH10TLB405ACL 6
9. Repeat steps 7 through 9 for the bottom king pin.

10. Remove the swivel housing.
RCPH10TLB956ABL 7
NOTE: Take care when removing shaft. Do not cut the seal and bushing the splines on the axle shaft.
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11. Repeat steps1 through 11 for the other swivel hous-

ing.
12. Remove the belleville washer from the top and bot-
tom of the axle housing.
RCPH10TLB699ABL 8
NOTE: Mark washers for reassembly.

13. Remove the top cylindrical bushing and bottom
spherical bushing. using an acceptable puller.
RCPH10TLB926ABL 9
14. Use an acceptable puller and remove the axle shaft

seal.
RCPH10TLB959ABL 10
15. Use an acceptable puller and remove the axle shaft

bushing.
RCPH10TLB492ABL 11
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16. Use a hammer and a chisel that has a long taper to

remove the bearing cone from the bottom king pin.
RCPH10TLB459ABL 12
Replacing a Universal Joint

17. Remove the four snap rings.
RCPH10TLB472ABL 13
18. Use the CAS1980 V-block to support the coupling.

Adjust the Allen bolts in the V-block to hold the cou-
pling level and use additional support as required.
Use an acceptable driver and press the bottom bear-
ing cap against the V-block.
RCPH10TLB599ABL 14
19. Fasten the bearing cap in a vise and drive the cou-
pling off the bearing cap.
RCPH10TLB473ABL 15
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20. Use the V-block to support the coupling and press

the other bearing cap against the V-block.
RCPH10TLB593ABL 16
21. Remove the long axle shaft (or short axle shaft) from
the coupling.
RCPH10TLB594ABL 17
22. Remove the coupling from the bearing cap.
RCPH10TLB596ABL 18
23. Use an acceptable support and driver to press the

bottom bearing cap out of the yoke as far as possible.
RCPH10TLB474ABL 19
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24. Remove the yoke from the bearing cap. DO NOT hit
the axle shaft in the seal area.
RCPH10TLB475ABL 20
25. Press the other bearing cap out of the yoke as far as
possible.
RCPH10TLB476ABL 21
26. Remove the cross.
RCPH10TLB477ABL 22
27. Use an acceptable driver and press the bearing cap

out of the yoke.
RCPH10TLB478ABL 23
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28. Press a bearing cap into the yoke until the top of the
bearing cap is 6 mm (0.24 in) above the top of the
yoke.
RCPH10TLB585ABL 24
29. Carefully install the cross in the bearing cap.
RCPH10TLB586ABL 25
30. Press the other bearing cap into the yoke until the
top of the bearing cap is 9 mm (0.35 in) above the
top of the yoke.
RCPH10TLB587ABL 26
31. Carefully raise the cross into the bearing cap so that
the cross is in both bearing caps.
RCPH10TLB588ABL 27
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32. Hold the cross and press the bearing caps into the
yoke.
RCPH10TLB589ABL 28
33. Use an acceptable driver and press a bearing cap

into the yoke so that a snap ring can be installed.
RCPH10TLB590ABL 29
34. Install a snap ring.
RCPH10TLB591ABL 30
35. Repeat steps 30 and 31 for the other bearing cap.

36. Use the V-block to support the coupling and press a
bearing cap into the coupling even with the OD of the
coupling.
RCPH10TLB592ABL 31
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RCPH10TLB595ABL 32
38. Use an acceptable driver and press the other bearing

cap into the coupling until the top of the bearing cap
is 6 mm (0.24 in) above the top of the coupling.
RCPH10TLB597ABL 33
39. Carefully raise the cross into the top bearing cap so
that the cross is in both bearing caps.
RCPH10TLB598ABL 34
40. Hold the cross and press the bearing cap into the
coupling so that a snap ring can be installed.
RCPH10TLB600ABL 35
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RCPH10TLB601ABL 36
Next operation:
Axle housing - Assemble (25.100)
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Axle housing - Assemble - CNH Front Axle- Four Wheel Drive

1. Drive the bushing into the bore until the bushing is
3.175 mm (0.125 in) beyond the end of the bore.
Then install the seal. Use DMT100005 for the bush-
ing and DMT100006 for the seal.
RCPH10TLB994ABL 1
2. Install the cylindrical bushing for the top king pin on a

driver that has a pilot. Drive the bushing all the way
into the bore until fully seated.
RCPH10TLB490ABL 2
NOTE: Freezing of part to enable assembly is acceptable.

3. Repeat step 2 for the bottom bushing.
4. Insert shaft without cutting seal. Maneuver shaft to
align splines with the differential.
RCPH10TLB956ABL 3
NOTE: Take care not to cut seal during installation. It is necessary to rotate the input shaft to align splines.
47365539 08/07/2012
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5. Install the belleville washer on the top of the axle

housing. Then install the belleville washer on the
bottom of the axle housing. Make final adjustments
of the swivel housing to align king pins..
RCPH10TLB002ACL 4
6. Install the top king pin, and bolts. Tighten the bolts
(3) to a torque of 154 - 188 N·m (113.6 - 138.7 lb ft).
RCPH10TLB004ACL 5
7. Install the bottom king pin and bolts. Tighten the bolts
(3) to 154 - 188 N·m (113.6 - 138.7 lb ft). If bearing
cone is removed in the previous step replace with
new cone at this time.
RCPH10TLB497ABL 6
8. Install the ball joint and new nut.
RCPH10TLB005ACL 7
NOTE: Nut must be replaced with new nut each time it is removed.
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9. Tighten the nut for models 580N & 580SN to: 129 -
160 N·m (95.1 - 118.0 lb ft) Tighten the nut for mod-
els 580SN-WT & 590SN to: 162 - 200 N·m (119.5 -
147.5 lb ft).
RCPH10TLB006ACL 8
10. Repeat steps 1 through 9 for the opposite end of the

axle.
11. Lubricate the king pins.
12. Assemble the planetary according to instructions
Planetary drive and hub - Assemble (25.108).
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Axle housing - Disassemble - Carraro Front axle-four wheel drive

swivel housing and universal joint- 580N and 580SN only
1. Do the necessary steps under Disassembly of plan-
etary for access to the swivel housing.
2. Loosen the nut.
RCPH10TLB693ABL 1
3. Use the CAS10468 puller to loosen the ball joint.

Remove the nut and remove the ball joint from the
swivel housing.
RCPH10TLB692ABL 2
4. Loosen the bolts that hold the top king pin.
RCPH10TLB695ABL 3
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5. Fasten acceptable lifting equipment as shown. Re-

move the bolts and use acceptable tools to remove
the top king pin.
RCPH10TLB697ABL 4
6. Repeat steps 4 and 5 for the bottom kin pin.

RCPH10TLB698ABL 5
8. Remove the belleville washer from the bottom of the

axle housing.
RCPH10TLB699ABL 6
9. Remove the belleville washer from the top of the axle

housing.
RCPH10TLB640ABL 7
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10. Use an acceptable puller and remove the top and

bottom bushings.
RCPH10TLB489ABL 8
11. Use an acceptable puller and remove the seal.
RCPH10TLB491ABL 9
12. Use an acceptable puller and remove the bushing.
RCPH10TLB492ABL 10
13. Use an acceptable puller and remove the seal from

the swivel housing.
RCPH10TLB456ABL 11
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14. Support the swivel housing on a sleeve and press the

bushing out of the swivel housing.
RCPH10TLB457ABL 12
15. Use a hammer and a chisel that has a long taper to

start the bushing off the bottom of the kin pin.
RCPH10TLB459ABL 13
16. Press the bottom kin pin out of the bushing.
RCPH10TLB460ABL 14
Replacing a universal joint

RCPH10TLB472ABL 15
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18. Use the CAS1980 V-block to support the coupling.

Adjust the allen bolts in the V-block to hold the cou-
RCPH10TLB599ABL 16
19. Fasten the bearing cap in a vise and drive the cou-
pling off the bearing cap.
RCPH10TLB473ABL 17

RCPH10TLB593ABL 18
the coupling.
RCPH10TLB594ABL 19
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22. Remove the coupling from the bearing cap.
RCPH10TLB596ABL 20

RCPH10TLB474ABL 21
24. Remove the yoke from the bearing cap. DO NOT hit
the axle shaft in the seal area.
RCPH10TLB475ABL 22
possible.
RCPH10TLB476ABL 23
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RCPH10TLB477ABL 24

out of the yoke.
RCPH10TLB478ABL 25
28. Press a bearing cap into the yoke until the top of the
bearing cap is 6 MM. (1/4 inch) above the top of the
yoke.
RCPH10TLB585ABL 26
RCPH10TLB586ABL 27
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30. Press the other bearing cap into the yoke until the
top of the bearing cap is 9 MM. (3/8 inch) above the
top of the yoke.
RCPH10TLB587ABL 28
31. Carefully raise the cross into the bearing cap so that.
RCPH10TLB588ABL 29
yoke.
RCPH10TLB589ABL 30

RCPH10TLB590ABL 31
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RCPH10TLB591ABL 32
35. Repeat steps 31and 32for the remaining bearing

cap.
coupling.
RCPH10TLB592ABL 33
RCPH10TLB595ABL 34

cap into the coupling until the top of the bearing cap
is 6 MM. (1/4 inch) above the top of the coupling.
RCPH10TLB597ABL 35
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RCPH10TLB598ABL 36
RCPH10TLB600ABL 37
RCPH10TLB601ABL 38
Next operation:
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Axle housing - Assemble - Carraro Front axle-four wheel drive

swivel housing and universal joint- 580N and 580SN only
1. Drive the bushing into the bore until the bushing is 8
MM. (5/16 inch) beyond the end of the bore. Then
install the seal.
RCPH10TLB493ABL 1
2. Install the bushing for the top king pin on a driver that
has a pilot and drive the bushing all the way into the
bore.
RCPH10TLB490ABL 2
3. Repeat step 2for the bottom bushing.

4. Install the belleville washer on the top of axle frame.
Then install the belleville washer on the bottom of the
axle frame. Install the swivel housing.
RCPH10TLB698ABL 3
5. Install the top king pin, belleville washer, spacer, and

bolts. Tighten the bolts to a torque of 120 Nm (88.5
pound-feet).
RCPH10TLB696ABL 4
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6. Install the bottom king pin, belleville washer and self-

locking bolts. Tighten the bolts to 120 Nm (88.5
pound-feet).
RCPH10TLB497ABL 5
7. Install the ball joint and nut.
RCPH10TLB498ABL 6
8. Tighten the nut to 165 Nm (122 pound-feet).
RCPH10TLB693ABL 7

axle.
11. Assemble the planetary according to instructions.
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Axle housing - Disassemble - Carraro Front axle-four wheel drive

swivel housing- 580SN-WT and 590SN only
1. Loosen but do not remove the tie rod nut.
RCPH10TLB482ABL 1
2. Use the CAS-10468 puller to loosen the ball joint.
RCPH10TLB483ABL 2
3. Remove the nut and remove the ball joint from the
swivel housing.
RCPH10TLB484ABL 3
4. Loosen and remove the self-locking bolts that hold

the top king pin.
RCPH10TLB486ABL 4
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5. Remove the top king pin.
RCPH10TLB487ABL 5
6. Repeat steps 4 and 5 for the bottom king pin.

RCPH10TLB488ABL 6
8. Remove the bellville washer and spacer for the top.

Remove the bellville washer from the bottom.
RCPH10TLB640ABL 7
9. Remove the axle shaft.
RCPH10TLB488ABL 8
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10. Use an acceptable puller and remove the top and

bottom bushings.
RCPH10TLB489ABL 9
11. Use an acceptable puller and remove the seal.
RCPH10TLB491ABL 10
12. Use an acceptable puller and remove the bushing.
RCPH10TLB492ABL 11
13. Use an acceptable puller and remove the seal from

the swivel housing.
RCPH10TLB456ABL 12
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14. Support the swivel housing on a sleeve and press the

bushing out of the swivel housing.
RCPH10TLB457ABL 13
15. Use a soft-faced hammer and a chisel that has a long

taper to start the bushing off the bottom king pin.
RCPH10TLB459ABL 14
16. Press the bottom king pin out of the bushing.
RCPH10TLB460ABL 15
Replacing a universal joint

RCPH10TLB472ABL 16
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18. Use the CAS-1980 V-block to support the coupling.

Adjust the Allen bolts in the V-block to hold the cou-
RCPH10TLB599ABL 17
19. Fasten the bearing cap in a vise and use a soft-faced

hammer to drive the coupling off the bearing cap.
RCPH10TLB473ABL 18

RCPH10TLB593ABL 19
the coupling.
RCPH10TLB594ABL 20
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22. Use a soft-faced hammer to remove the coupling

from the bearing cap.
RCPH10TLB596ABL 21

RCPH10TLB474ABL 22
24. Use a soft-faced hammer to remove the yoke from

the bearing cap. DO NOT hit the axle shaft in the
seal area.
RCPH10TLB475ABL 23
possible.
RCPH10TLB476ABL 24
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RCPH10TLB477ABL 25

out of the yoke.
RCPH10TLB478ABL 26
28. Press a bearing cap into the yoke 6mm (1/4 inch)
from the top of the yoke.
RCPH10TLB585ABL 27
29. Carefully install the cross into the bearing cap.
RCPH10TLB586ABL 28
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30. Press the other bearing cap into the yoke 9mm (3/8
inch) from the tops of the yoke.
RCPH10TLB587ABL 29
31. Carefully raise the cross into the bearing cap so that
RCPH10TLB588ABL 30
yoke.
RCPH10TLB589ABL 31

RCPH10TLB590ABL 32
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RCPH10TLB591ABL 33

coupling.
RCPH10TLB592ABL 34
RCPH10TLB595ABL 35

cap into the coupling 6mm (1/4 inch) from the top of
the coupling.
RCPH10TLB597ABL 36
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RCPH10TLB598ABL 37
RCPH10TLB600ABL 38
RCPH10TLB601ABL 39
Next operation:
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Axle housing - Assemble - Carraro Front axle-four wheel drive

swivel housing- 580SN-WT and 590SN only
1. Use a soft-faced hammer to drive the bushing into the
bore until the bushing is 8 mm (5/16 inch) beyond the
end of the bore. The install the seat.
RCPH10TLB493ABL 1
2. Use a soft-faced hammer to install the bushing for

the top king pin on a driver that has a pilot and drive
the bushing all the way into the bore.
RCPH10TLB490ABL 2
3. Repeat step 2 for the bottom bushing.

4. Use a soft-faced hammer to install the axle shaft.
RCPH10TLB494ABL 3
5. Install the swivel housing.
RCPH10TLB488ABL 4
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6. Install the top king pin, beveled washer, spacer, and

self-locking bolts.
RCPH10TLB495ABL 5
7. Tighten the self-locking bolts to 190 Nm (141 pound-

feet).
RCPH10TLB485ABL 6
8. Install the bottom king pin, beveled washer, and self-

locking bolts.
RCPH10TLB496ABL 7
9. Tighten the self-locking cap screws to 190 Nm (141

pound-feet).
RCPH10TLB497ABL 8
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10. Install the ball joint and nut.
RCPH10TLB498ABL 9
11. Tighten the nut to: 580SN - WT 165Nm (122 pound

feet) and 590SN - 220 Nm (162 pound-feet).
RCPH10TLB499ABL 10

axle.
14. Assemble the planetary according to instructions in
this section.
Next operation:
Differential - Remove (25.102)
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Index

Axle housing - Assemble - CNH Front Axle- Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Axle housing - Assemble - Carraro Front axle-four wheel drive swivel housing and universal joint- 580N and 580SN
only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Axle housing - Assemble - Carraro Front axle-four wheel drive swivel housing- 580SN-WT and 590SN only . . . 64
Axle housing - Disassemble - CNH Front Axle -Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Axle housing - Disassemble - Carraro Front axle-four wheel drive swivel housing and universal joint- 580N and
580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Axle housing - Disassemble - Carraro Front axle-four wheel drive swivel housing- 580SN-WT and 590SN only 54
Axle housing - Exploded view - CNH Front axle - swivel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Axle housing - Exploded view - Carraro Front axle- swivel housing- . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Four-Wheel drive (4WD) axle - Drawing - Front axle-four wheel drive- measuring toe-in . . . . . . . . . . . . . . . . . . . . 20
Four-Wheel drive (4WD) axle - Exploded view - CNH Four wheel drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Four-Wheel drive (4WD) axle - General specification - CNH Front Axle Four Wheel Drive - 580N and 580SN . . . 4
580N, 580SN
Four-Wheel drive (4WD) axle - General specification - CNH Front Axle Four Wheel Drive - 580SN-WT and 590SN
.................................................................................................. 4
580SN WT NA, 590SN
Four-Wheel drive (4WD) axle - General specification - Carraro Front axle-four wheel drive - 580N and 580SN only
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
580N, 580SN
Four-Wheel drive (4WD) axle - General specification - Carraro Front axle-four wheel drive - 580SN-WT and 590SN
only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
580SN WT NA, 590SN
Four-Wheel drive (4WD) axle - Install - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
580N, 580SN, 580SN WT NA, 590SN
Four-Wheel drive (4WD) axle - Remove - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
580N, 580SN, 580SN WT NA, 590SN
Four-Wheel drive (4WD) axle - Special tools - CNH Front Axle Four Wheel Drive - 580N, 580SN, 580SN-WT, 590SN
.................................................................................................. 5
580N, 580SN, 580SN WT NA, 590SN
Four-Wheel drive (4WD) axle - Special tools - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . 11
580N, 580SN
Four-Wheel drive (4WD) axle - Special tools - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only 15
580SN WT NA, 590SN
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Front bevel gear set and differential - 102
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Differential
Exploded view - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . 6
Exploded view - Carraro Front axle-four wheel drive limited slip differential- 580SN-WT and 590SN only 8
Exploded view - CNH- Front Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE
Differential
Remove - CNH Front Axle -Four Wheel Drive - Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassemble - CNH Front Axle -Four Wheel Drive- Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassemble - CNH Front Axle -Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspect - CNH Front Axle - Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assemble - CNH Front Axle - Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Assemble - CNH Front Axle - Four Wheel Drive - Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Remove - Carraro Front axle-four wheel drive differential carrier- 580N and 580SN only . . . . . . . . . . . . 34
Disassemble - Carraro Front axle-four wheel drive differential carrier- 580N and 580SN only . . . . . . . . 37
Disassemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . 42
Inspect - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Assemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Assemble - Carraro Front axle-four wheel drive differential carrier- 580N and 580SN only . . . . . . . . . . . 50
Remove - Carraro Front axle-four wheel drive differential carrier- 580SN-WT and 590SN only . . . . . . . 62
Disassemble - Carraro Front axle-four wheel drive differential carrier- 580SN-WT and 590SN only . . . 65
Disassemble - Carraro Front axle-four wheel drive - differential - 580SN-WT and 590SN only . . . . . . . 70
Inspect - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . 73
Assemble - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . 74
Assemble - Carraro Front axle-four wheel drive differential carrier- 580SN-WT and 590SN only . . . . . . 79
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Front axle system - Front bevel gear set and differential
Differential - Exploded view - Carraro Front axle-four wheel drive -

580N and 580SN only
1. Cover 12. O-ring
2. Seal 13. Lock
3. Pinion nut 14. Shim
4. Washer 15. Pinion gear
5. Bearing 16. Ring gear
6. Flat washer 17. Case half
7. Spacer 18. Thrust washer
8. Bearing cup 19. Side gear
9. Differential carrier 20. Pinion gear
10. Adjusting ring 21. Pinion shaft
11. Bearing cap 22. Dowel pin
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RCPB10TLB002HAL 1
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Differential - Exploded view - Carraro Front axle-four wheel drive -

580SN-WT and 590SN only
1. Cover 12. O-ring
2. Seal 13. Lock
3. Pinion nut 14. Shim
4. Washer 15. Pinion gear
5. Bearing 16. Ring gear
6. Flat washer 17. Case half
7. Spacer 18. Thrust washer
8. Bearing cup 19. Side gear
9. Differential carrier 20. Pinion gear
10. Bearing cap 21. Pinion shaft
11. Bearing cap 22. Dowel pin
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RCPB10TLB002HAL 1
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Differential - Exploded view - Carraro Front axle-four wheel drive

limited slip differential- 580SN-WT and 590SN only
1. Locking plate and bolt 7. Friction plate special (2)
2. Ring nut 8. Thrust washer
3. Bearing 9. Side and pinion gears
4. Differential housing 10. Pin
5. Reaction plate (10) 11. Shaft
6. Friction plate (8) 12. Bolt (12)
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RCPH10TLB004GAL 1
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25.102 / 9
Differential - Exploded view - CNH- Front Axle - Differential

Differential
1. Differential Carrier 7. Crush sleeve 13. Side gear 19. Bolt 25. Bolts
2. Cover 8. Bearing 14. Thrust Washer 20. Bearing caps 26. Locking finger
bolts
3. O-ring 9. Spacer 15. Differential 21. Side gear 27. Locking pin for
housing diff. cross shaft
4. Seal 10. Pinion shaft 16. Bearing 22. Crown gear 28. Differential cross
shaft
5. Outboard bearing 11. Thrust Washer 17. Spanner nut 23. Bearing
6. Washer 12. Spider gear 18. Locking finger 24. Spanner nut
47365539 08/07/2012
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RCPH10TLB171GAL 1
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Differential - Remove - CNH Front Axle -Four Wheel Drive -

Differential Carrier
Prior operation:
Planetary drive and hub - Disassemble (25.108)
1. Drain oil.
RCPH10TLB276ACL 1
2. Remove knuckle assembly.

3. Loosen and remove the steering cylinder bolts and
washers.
RCPH10TLB957ABL 2
4. Remove the differential carrier bolts (12).
RCPH10TLB958ABL 3
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25.102 / 12
5. Use suitable lifting equipment and remove the differ-

ential carrier.
RCPH10TLB255ACL 4
Next operation:
Differential - Disassemble (25.102)
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Differential - Disassemble - CNH Front Axle -Four Wheel Drive-

1. See differential and differential carrier and exploded
view Differential - Exploded view (25.102)
2. Place the differential on an approved working area
so the differential gear is free to rotate.
RCPH10TLB962ABL 1
3. Prevent the pinion shaft from turning. Measure the

backlash of the ring gear. Record the reading.
RCPH10TLB963ABL 2
4. Make an identification mark on the bearing cap and

leg on one side of the differential carrier.
RCPH10TLB964ABL 3
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5. Loosen the bolt.
RCPH10TLB964ABL 4
6. Loosen both adjusting rings. Use DMT100002 tool or

suitable alternative, such as CAS1840C, if available.
RCPH10TLB964ABL 5
NOTE: Record the number of turns while removing the nuts.

7. Remove the bolts. Loosen the 2 bearing caps.
RCPH10TLB966ABL 6
8. Remove the adjusting rings, bearing cups and differ-

ential.
RCPH10TLB989ABL 7
9. If the bearing cups are to be used again, fasten an

identification tag to one bearing cup for the current
installation.
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10. Remove the seal and cover.
RCPH10TLB972ABL 8
11. Use a very narrow chisel/round end punch to unstake

the nut.
RCPH10TLB512ABL 9
12. Use special tool 380000468 and 380100102 or yolk

to remove the pinion nut.
RCPH10TLB263ACL 10
13. Remove the tab washer.
RCPH10TLB976ABL 11
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25.102 / 16
14. Use a press and drive the pinion shaft out of the outer
bearing.
RCPH10TLB977ABL 12
NOTE: Take care to avoid pinion shaft falling on the ground.

15. Remove the flat washers and crush sleeve. Discard
the crush sleeve. The crush sleeve MUST NOT be
used again.
RCPH10TLB978ABL 13
16. Press the pinion shaft out of the inner bearing.
RCPH10TLB979ABL 14
RCPH10TLB535ABL 15
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25.102 / 17
18. Use a soft punch to remove the bearing cups only if

inspection indicates the need for new parts.
RCPH10TLB531ABL 16
19. Use an acceptable puller to remove the seal from the

cover, if needed. Discard the seal.
RCPH10TLB713ABL 17
20. Remove and discard the O-ring from the cover.
RCPH10TLB974ABL 18
Next operation:
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Differential - Disassemble - CNH Front Axle -Four Wheel Drive

1. Remove the bolts (12).
RCPH10TLB967ABL 1
2. Use a soft faced hammer to remove the ring gear and

bushings.
RCPH10TLB968ABL 2
3. Remove the outer side gear, as required.
RCPH10TLB970ABL 3
4. Use a suitable punch to remove retaining pin.
RCPH10TLB928ABL 4
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25.102 / 19
5. Remove cross pin.
RCPH10TLB930ABL 5
6. Remove the thrust washer, spider gears and remain-

ing side gear, as required.
RCPH10TLB931ABL 6
Next operation:
Differential - Inspect (25.102)
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Differential - Inspect - CNH Front Axle - Four Wheel Drive

1. Clean all parts in cleaning solvent.
2. Inspect all bearing assemblies for flat areas, pitting,
scoring, and other damage. Also check the races for
damage. If any of these defects are found, a new
wheel bearing and bearing cup must be installed.
3. Inspect the teeth on the pinion gear and ring gear for
pitting, scoring, and broken teeth. The ring gear and
pinion gear must be replaced as a set.
4. Inspect the side gears, the cross pin, and the teeth of
the spider gears for pitting, scoring, and other dam-
age. Also inspect the thrust surfaces and the bore of
each spider gear. Check the splines (limited slip op-
tion only) in the side gears for wear. Use new parts
as required. Differential gears must be replaced as
a set.
5. Inspect the thrust washers for pitting, scoring, and
other damage. Use new parts as required.
6. Inspect the spider shaft for wear. If wear can be felt
with a finger nail, then replace.
Next operation:
Differential - Assemble (25.102)
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Differential - Assemble - CNH Front Axle - Four Wheel Drive

NOTE: For limited slip differentials install 5 reaction and 4 friction plates starting with a reaction plate. Make sure the
one sided friction plate with friction material on one side is placed against the side gear with the friction material facing
away from the gear.
1. Install the thrust gear and washer, as required.
RCPH10TLB931ABL 1
2. Install the cross pin and spider gears.
RCPH10TLB930ABL 2
NOTE: For limited slip option: Install one spider and washer with differential shaft, then insert second spider and
washer rolling next to first one. Hold up the side gear and roll spider and washer into place. Then push the shaft
through the second spider. Finish inserting plates.
3. Use a suitable punch to install the retaining pin.
RCPH10TLB928ABL 3
NOTE: Grease all gear and plate contact surfaces before assembly with specified oil.
47365539 08/07/2012
25.102 / 22
4. Install the outer side gear.
RCPH10TLB970ABL 4
5. Make sure that the mounting surfaces for the ring

gear are clean and install the ring gear.
RCPH10TLB987ABL 5
6. Use the vise to prevent the differential from turning

and install and tighten the (12) bolts to 96 - 118 N·m
(70.8 - 87.0 lb ft). Tighten in a star pattern and use
medium thread Loctite 242.
RCPH10TLB988ABL 6
Next operation:
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Differential - Assemble - CNH Front Axle - Four Wheel Drive -

1. Use a suitable driver and drive the bearing cup(s) into
the differential carrier. Use a feeler gauge to ensure
cups are fully seated to 0.008 mm (0.003 in).
RCPH10TLB532ABL 1
2. Install the spacer. The chamfer on the ID of the

spacer must be towards the pinion gear.
RCPH10TLB535ABL 2
3. Use a suitable tool and press the inner bearing

against the spacer. Use a feeler gauge to ensure
bearing is fully seated.
RCPH10TLB981ABL 3
NOTE: Bearing heating is permitted as long as checked with feeler gauge when bearing is cooled.
4. Lubricate the bearings with gear lubricant.
RCPH10TLB542ABL 4
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25.102 / 24
5. Install a new crush sleeve and two flat washers. The

old crush sleeve MUST NOT be used again. One flat
washer goes on each side of the crush sleeve.
RCPH10TLB533ABL 5
6. Install the pinion shaft and the outer bearing.
RCPH10TLB982ABL 6
7. Install the tab washer, round edges down.
RCPH10TLB983ABL 7
8. Install a new pinion nut.
RCPH10TLB984ABL 8
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25.102 / 25
9. Use the yoke and 380000468 wrench for the follow-

ing procedure.
RCPH10TLB263ACL 9
10. The pinion shaft and bearings will still be loose.

Tighten the pinion nut in SMALL amounts until the
bearings becomes seated.
NOTICE: If the pinion nut is tightened too much (rotating torque more than specified), the pinion will have to be re-
moved and a new crush sleeve installed on the pinion shaft.
11. Use 380100102 and a pound-inch torque wrench to
check the rotating torque of the pinion shaft. The
shaft must be rotated during tightening of the nut.
Final reading to be verified after 3 complete revolu-
tions of the shaft. The rotating torque must be 1.7 -
2.2 N·m (15.0 - 19.5 lb in). If the rotating torque is
less than specified, tighten the pinion nut a SMALL
amount and check the rotating torque again. Record
actual rolling torque for later use.
RCPH10TLB546ABL 10
12. When the rotating torque is as specified, use a ham-

mer and punch and drive part of the pinion nut into
the slot in the pinion shaft.
RCPH10TLB985ABL 11
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13. Install the differential carrier and lubricate the bear-

ings with gear lubricant.
RCPH10TLB989ABL 12
14. Install bearing cups and bearing caps with the align-
ment marks.
RCPH10TLB990ABL 13
15. Tighten the bolts to pull the bearing caps against the
differential carrier. Do not overtighten the bolts. The
bearings must be able to rotate. Tighten to 20 N·m
(14.8 lb ft)
RCPH10TLB990ABL 14
USED BEVEL SET

NOTE: All bearings in axle should get a few drops of oil before setup. Never rotate the axle dry.
16. Use the CAS1840C or DMT100002 and tighten both
adjusting rings while making sure that there is clear-
ance (backlash) between the ring gear and pinion
gear. Bring adjusting rings into position using the
counted turns from Step 5 of the disassembly sec-
tion Differential - Disassemble (25.102). Small fi-
nal alignment may be needed to align marks. Verify
locking finger is aligned.
RCPH10TLB715ABL 15
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25.102 / 27
17. Tighten the adjusting nut on gear teeth side, to get

rolling torque measured on pinion shaft. See chart
below:
Diff Preload (Nm)

Measured at Pinion
Pinion, Z Crown Z Bevel Ratio FD Ratio Total Ratio Min Max
16 32 2.0 6.0 12.0 0.75 1.25
14 32 2.3 6.0 13.7 0.66 1.09
15 32 2.1 6.0 12.8 0.70 1.17
14 32 2.3 6.0 13.7 0.66 1.09
13 31 2.4 6.0 14.3 0.63 1.05
14 31 2.2 6.0 13.3 0.68 1.13
13 35 2.7 6.0 16.2 0.56 0.93
18. In chart above using Total Ratio field (12.0) as a ref-

erence. Use value from step 20 to determine differ-
ential preload. So: a value of 2.0 Nm would result in
a minimum value of 2.75 Nm and a maximum value
of 3.25 Nm.
19. Rotate bevel set approximately 3 or 4 turns, ensure
proper seating. Use a dial indicator to check for back-
lash. Check in 3 places, approximately 120 degrees
apart. Current value should be (0.008 - 0.013 in). . If
values vary more than (0.005 in), then replace bevel
set. .
RCPH10TLB991ABL 16
20. If backlash value is to large, loosen the adjusting nut

1 slot on gear side and tighten the adjusting nut 1
slot on the back face of the bevel gear. Recheck
backlash. Each slot ~ .004 in.
21. If the backlash value is to small, do the opposite of
step 20.
22. Confirm backlash with dial indicator. Value should be
(0.008 in - 0.013 in).
RCPH10TLB992ABL 17
23. Make final adjustment of nuts to align locking fingers

and confirm rolling torque. See chart, step 17.
47365539 08/07/2012
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24. Apply bevel set pattern yellow compound in 3 places

120 degrees apart, on 3 teeth each. Rotate bevel set
enough to see pattern in yellow compound. Pattern
should be per chart below. Normal wear will flatten
(elongate) the contact pattern.
NOTE: This is a nonadjustable bevel set. If pattern is significantly different than spec, then replace bevel set.
25. If the original ring gear and pinion gear are being
used, the backlash should be close to the measure-
ment made during disassembly.
RCPH10TLB352ACL 18
26. When the backlash is correct, tighten the bolts to 96

- 118 N·m (70.8 - 87.0 lb ft).
RCPH10TLB990ABL 19
27. Install the lock bolt and lock washer that hold each
adjusting ring. Tighten to 21 - 26 N·m (15.5 - 19.2 lb
ft)
28. Apply form-in-place gasket material, Loctite 515.
RCPH10TLB995ABL 20
47365539 08/07/2012
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NEW BEVEL SET

29. Install the adjusting rings. Turn nuts into position.
Leave enough clearance on gear teeth side nut to
prevent any bearing preload while tightening the ad-
justing nut on back face of bevel gear. Tighten to
zero backlash.
RCPH10TLB715ABL 21
NOTE: All bearings in axle should get a few drops of oil before setup. Never rotate the axle dry.
30. Tighten the adjusting nut on gear teeth side, to get
rolling torque measured on pinion shaft. See chart
below: In chart above using Total Ratio field (12.0)
as a reference. Use value from step 20 to determine
differential preload. So: a value of 2.0 Nm would re-
sult in a minimum value of 2.75 Nm and a maximum
value of 3.25 Nm.
Diff Preload (Nm)

Measured at Pinion
Pinion, Z Crown Z Bevel Ratio FD Ratio Total Ratio Min Max
16 32 2.0 6.0 12.0 0.75 1.25
14 32 2.3 6.0 13.7 0.66 1.09
15 32 2.1 6.0 12.8 0.70 1.17
14 32 2.3 6.0 13.7 0.66 1.09
13 31 2.4 6.0 14.3 0.63 1.05
14 31 2.2 6.0 13.3 0.68 1.13
13 35 2.7 6.0 16.2 0.56 0.93
31. Rotate bevel set approximately 3 or 4 turns, ensure

proper seating of bearings. Use a dial indicator to
check for backlash. Check in 3 places, approxi-
mately 120 degrees apart. Current value should be
0. If values vary more than 0.005 inch, then replace
bevel set. If not, repeat steps 32 and 33 to get zero
backlash.
RCPH10TLB991ABL 22
32. Loosen the adjusting nut 2 teeth/slots on back face

of bevel gear. Tighten the adjusting nut on gear teeth
side the same amount. Maintain input rolling torque
throughout the process. Each slot ~ 0.00045 N·m
(0.004 lb in). Hold adjusting nut locking finger in
place and move adjusting nut to closest slot that al-
lows finger in slot.
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33. Check backlash with dial indicator. Value should be

(0.010 in). Try for lowest value.
RCPH10TLB992ABL 23
34. Make final adjustments to adjusting nuts to bring

backlash in line with step 33.
35. Confirm rolling torque per step 33:
36. If backlash value is to large, loosen the adjusting nut
1 slot on gear side and tighten the adjusting nut 1
slot on the back face of the bevel gear. Recheck
backlash. Each slot ~ (0.004) in.
37. If the backlash value is to small, do the opposite of
step 36.
38. Confirm backlash with dial indicator. Value should be
(0.010) in.
RCPH10TLB992ABL 24
39. Apply bevel set pattern yellow compound in 3 places

120 degrees apart, on 3 teeth each. Rotate bevel set
enough to see pattern in yellow compound. Pattern
should be per chart.
RCPH10TLB352ACL 25
NOTE: This is a non-adjustable bevel set. If pattern is significantly does not match, then replace bevel set.
NOTE: Each tooth is ~ 0.004 inches.
47365539 08/07/2012
25.102 / 31

- 118 N·m (70.8 - 87.0 lb ft).
RCPH10TLB990ABL 26
41. Install the locking finger bolts and lock washer that
hold each adjusting ring. Tighten to 21 - 26 N·m (15.5
- 19.2 lb ft)
42. Install a new O-ring on the cover.
RCPH10TLB973ABL 27
43. Use DMT100001 and drive a new seal into the cover.
The OD of the seal should be lightly coated with Klu-
berplus. The seal will be approximately 1/16 from the
inner face of the cover. Pack seal lips with approved
grease.
RCPH10TLB714ABL 28
44. Lubricate the O-ring with clean oil Powered front

axle - General specification (25.100). Install the
cover
RCPH10TLB264ACL 29
47365539 08/07/2012
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45. Apply form-in-place gasket material, Loctite 515.
RCPH10TLB995ABL 30
46. Install the differential carrier.
RCPH10TLB996ABL 31
47. Install and tighten the bolts to 96 - 118 N·m (70.8 -

87.0 lb ft).
RCPH10TLB997ABL 32
48. Proceed with knuckle installation procedure Axle

housing - Assemble (25.100)
49. See specifications for the correct lubricant for the
axle housing.
50. Lubricate the removed king pins with molydisulfide
grease.
51. Measuring to in, if required Four-Wheel drive (4WD)
axle - Drawing (25.100)
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Differential - Remove - Carraro Front axle-four wheel drive

differential carrier- 580N and 580SN only
1. Drain the lubricant from the center bowl.
2. Loosen the nut.
RCPH10TLB693ABL 1
3. Use the CAS10468 puller to loosen the ball joint.
RCPH10TLB692ABL 2
RCPH10TLB484ABL 3
5. Loosen and remove the bolts that hold the top king
pin.
RCPH10TLB695ABL 4
47365539 08/07/2012
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6. Fasten suitable lifting equipment as shown and re-

move the top king pin.
RCPH10TLB697ABL 5
7. Remove the planetary and axle assembly.
RCPH10TLB698ABL 6

axle.
9. Use tool 380100091 and loosen and remove the right
steering cylinder.
RCPH10TLB502ABL 7
10. Remove the fitting from the closed end of the steering
cylinder.
11. Remove the bolts.
RCPH10TLB639ABL 8
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12. Remove the plug from the cylinder.
RCPH10TLB287ABL 9
13. Remove the steering cylinder.
RCPH10TLB288ABL 10
RCPH10TLB508ABL 11

ential carrier.
RCPH10TLB509ABL 12
Next operation:
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Differential - Disassemble - Carraro Front axle-four wheel drive

1. Fasten the differential carrier in a repair stand.
RCPH10TLB462ABL 1

RCPH10TLB701ABL 2

leg on one side of the differential carrier.
RCPH10TLB702ABL 3
4. Remove the bolt and lock that hold each adjusting

ring.
RCPH10TLB703ABL 4
47365539 08/07/2012
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5. Loosen the bolts.
RCPH10TLB704ABL 5
6. Loosen both adjusting rings.
RCPH10TLB715ABL 6
7. Remove the 4 bolts. Use a hammer to loosen the 2

bearing caps.
RCPH10TLB706ABL 7
8. Remove the adjusting rings, bearing cups and differ-

ential.
RCPH10TLB707ABL 8

installation.
47365539 08/07/2012
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RCPH10TLB511ABL 9
11. Use a narrow chisel to push the nut out of the pinion
shaft.
RCPH10TLB512ABL 10
12. Use the yoke and CAS2151 tool to remove the pinion
nut.
RCPH10TLB471ABL 11
RCPH10TLB529ABL 12
47365539 08/07/2012
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14. Use a soft hammer and drive the pinion shaft out of
the outer bearing.
RCPH10TLB530ABL 13
15. Remove the flat washers and spacer. Discard the

spacer. The spacer MUST NOT be used again.
RCPH10TLB533ABL 14
RCPH10TLB534ABL 15
17. Remove the shim.
RCPH10TLB535ABL 16
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18. Remove the bearing cups only if inspection indicates

the need for new parts.
RCPH10TLB531ABL 17
19. Use an acceptable puller and remove the seal form

the cover.
RCPH10TLB713ABL 18
RCPH10TLB691ABL 19
Next operation:
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Differential - Disassemble - Carraro Front axle-four wheel drive -

580N and 580SN only
RCPH10TLB513ABL 1
2. Remove the ring gear.
RCPH10TLB514ABL 2
3. Separate the case halves.
RCPH10TLB515ABL 3
4. Remove the thrust washer and side gear.
RCPH10TLB516ABL 4
47365539 08/07/2012
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5. Remove the pinion shaft assembly and pin.
RCPH10TLB518ABL 5
6. Remove the side gear.
RCPH10TLB520ABL 6
RCPH10TLB521ABL 7
8. Remove and install new bushings in the case halves

as required.
RCPH10TLB522ABL 8
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9. Remove the bearing from either case half as shown.
RCPH10TLB464ABL 9
Next operation:
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Differential - Inspect - Carraro Front axle-four wheel drive - 580N

and 580SN only
2. Inspect the bearing cup and the rollers in the bear-
ings for flat areas, pitting, scoring, and other dam-
age. Also check the inner race for damage. If any of
these defects are found, a new bearing and bearing
cup must be installed.
4. Inspect the side gears, the pinion shaft, and the teeth
of the pinion gears for pitting, scoring, and other dam-
each pinion gear. Check the splines in the side gears
for wear. Use new parts as required.
Next operation:
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Differential - Assemble - Carraro Front axle-four wheel drive - 580N

and 580SN only
1. Use the CAS 2395 and press a new bearing onto
each case half.
RCPH10TLB463ABL 1
2. Find the case half that has the threaded holes. Make
sure that the threads are free of lubricant.
RCPH10TLB523ABL 2
3. Lubricate the thrust washers, pinion gears and pinion

shaft with gear lubricant.
RCPH10TLB524ABL 3
4. Install a thrust washer in the case half that has

threaded holes.
RCPH10TLB521ABL 4
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5. Install a side gear.
RCPH10TLB520ABL 5
6. Install the thrust washers and pinion gears on the

pinion shaft.
RCPH10TLB525ABL 6
7. Install the pin.
RCPH10TLB519ABL 7
8. Install the pinion shaft assembly.
RCPH10TLB518ABL 8
47365539 08/07/2012
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9. Apply 270 Loctite to the threads in the case half.
RCPH10TLB526ABL 9
10. Install the other side gear.
RCPH10TLB517ABL 10
11. Install the other thrust washer in the other case half.
RCPH10TLB527ABL 11
NOTE: For limited slip differentials install 5 reaction and 4 friction plates starting with a reaction plate. Make sure the
special friction plate is against the side gear.
12. Using the two reference notches on the case halves,
assemble the two case halves.
RCPH10TLB515ABL 12
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13. Make sure the mounting surfaces for the ring gear
are clean and install the ring gear.
RCPH10TLB514ABL 13
14. Use the press to prevent the differential from turning

and install and tighten the bolts to 95 Nm (70 pound-
ft).
RCPH10TLB528ABL 14
Next operation:
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Differential - Assemble - Carraro Front axle-four wheel drive

1. Use a suitable driver and drive the bearing cup(s) into
the differential carrier.
RCPH10TLB532ABL 1
2. Assemble the gauge block, pilot and stud from the

CAS1839 pinion setting kit.
3. Install the gauge block, pilot, bearings and handle.
See special tools. Tighten the handle until the bear-
ings become difficult to turn.
RCPH10TLB537ABL 2
4. Install the gauge tube and bearing caps with marks

aligned.
RCPH10TLB538ABL 3
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5. Tighten the bolts to 156Nm (115 pound-feet).
RCPH10TLB539ABL 4
6. Use the metric feeler gauge and measure the space

between the gauge block and the gauge tube. Write
the measurement on line "b"in step 8.
RCPH10TLB540ABL 5
7. Write the number on the end of the pinion shaft on

line "d" in step 8.
RCPH10TLB458ABL 6
8. The number on line "a" does not change. Add line "a"
and line "b" and write the answer on link "c". Subtract
line "d" from line "c" and write the answer on line "e".
Line "e" is the thickness of the shim to be installed on
the pinion shaft. Example: Use 2.75 MM. thick shim
A. 109.75 MM A. 109.75 MM
B.+ MM B. +0.45 MM
C. MM C. 110.20MM
D. - MM D. -107.45MM
E. MM E. 2.75 MM
47365539 08/07/2012
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9. Remove the bolts, bearing caps, gauge tube, handle,

gauge block assembly and the bearings.
RCPH10TLB541ABL 7
10. Install the shim with the thickness specified in step 8.

The chamfer on the ID of the shim must be towards
the pinion gear.
RCPH10TLB535ABL 8
11. Use the CAS2370 inner/outer pinion bearing cone in-

staller and press the inner bearing against the shim.
RCPH10TLB536ABL 9
RCPH10TLB542ABL 10
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13. Install a new spacer and flat washers. The old spacer
MUST NOT be used again.
RCPH10TLB533ABL 11
RCPH10TLB543ABL 12
RCPH10TLB544ABL 13
RCPH10TLB545ABL 14
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17. Use the yolk and the CAS2151 wrench and tighten
the pinion nut to 68Nm (50 pound-feet).
RCPH10TLB470ABL 15

bearings become seated.
NOTE: If the pinion nut is tightened too much (rotating torque more than specified), the pinion will have to be removed
and a new spacer installed on the pinion shaft.
19. The art shows a socket being used, use the
CAS2375 and a pound-inch torque wrench to check
the rotating torque of the pinion shaft. The ro-
tating torque must be 1.7 to 2.2 Nm (15 to 20
pound-inches). If the rotating torque is less than
specified, tighten the pinion nut a SMALL amount
and check the rotating torque again.
RCPH10TLB546ABL 16
20. When the rotating torque is as specified, use a ham-

mer and punch and drive part of the pinion nut into
the slot in the pinion shaft.
RCPH10TLB547ABL 17
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RCPH10TLB691ABL 18
22. Use a suitable driver and drive a new seal into the
cover.
RCPH10TLB714ABL 19
23. Put the CAS2369 seal protector on the pinion shaft.
RCPH10TLB709ABL 20
24. Lubricate the O-ring and the seal with clean oil. In-
stall the cove.
RCPH10TLB710ABL 21
47365539 08/07/2012
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RCPH10TLB707ABL 22
26. Install the bearing cups and bearing caps with the
alignment marks.
RCPH10TLB700ABL 23
27. Tighten the bolts to pull the bearing caps against the
bearings must be able to rotate.
RCPH10TLB704ABL 24
28. Install the adjusting rings.
RCPH10TLB715ABL 25
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29. Use the CAS1840C and tighten both adjusting rings

while making sure that there is clearance (backlash)
between the ring gear and pinion gear.
RCPH10TLB715ABL 26
30. Use a dial indicator to check for end play.
RCPH10TLB555ABL 27
31. If there is end play, tighten the adjusting ring on the

tooth side of the ring gear until there is no end play.
32. If there is no end play, loosen the adjusting ring on the
back face side of the ring gear to make sure that there
is clearance between the ring gear and pinion gear
and tighten the opposite adjusting ring until there is
no end play.
33. When there is no end play, tighten each adjusting
ring one notch.
34. Use the dial indicator and check the backlash for the
ring gear at 90 degree intervals. If the reading are not
equal, adjust the backlash at the position that had the
smallest reading.
RCPH10TLB701ABL 28
used, the backlash must be equal to the measure-
36. If a new ring and pinion gear ar being used, the back-
lash must be 0.002 to 0.0025 MM )0.008 to 0.010
inch)
47365539 08/07/2012
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37. If there is not enough backlash, use the CAS1840C

and loosen the adjusting ring on the back face side
of the ring gear one notch and tighten the opposite
adjusting ring one notch. Check the backlash again.
Continue with this step until the backlash is correct.
RCPH10TLB715ABL 29
38. If there is too much backlash, use the CAS1840C

and loosen the adjusting ring on the tooth side of the
ring gear one notch and tighten the opposite adjust-
ing ring one notch. Check the backlash again. Con-
tinue with this step until the backlash is correct.
RCPH10TLB557ABL 30

Nm (197 pound-feet).
RCPH10TLB705ABL 31
40. Install the lock, bolt and lock washer that hold each
adjusting ring. Tighten the bolts to 13 Nm (120
pound-inches).
RCPH10TLB708ABL 32
47365539 08/07/2012
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41. Apply form-in-place gasket material.
RCPH10TLB559ABL 33
RCPH10TLB560ABL 34
43. Install and tighten the bolts to 169 Nm (125 pound-

feet).
RCPH10TLB508ABL 35
44. Install the steering cylinder.

feet).
RCPH10TLB504ABL 36
47365539 08/07/2012
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46. Install and tighten the tie rod using the 380100091
for the 580N and 580SN and torque to 300 Nm (222
pound-feet)
RCPH10TLB503ABL 37
47. Install and tighten the fitting at the closed end of the
steering cylinder.
48. Install the planetary and axle assembly. It may be
necessary to have another person turn the pinion
shaft.
RCPH10TLB698ABL 38
49. Install the top kin pin, spacer, and bolts. Tighten the
bolts to a torque of 120 Nm (89 pound-feet).
RCPH10TLB696ABL 39
50. Install the bottom kin pin, belleville washer and bolts.
Tighten the bolts to a torque of 120 Nm (89 pound-
feet).
47365539 08/07/2012
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51. Install the ball join and nut.
RCPH10TLB498ABL 40
52. Tighten the nuts to 165 Nm (122 pound-feet).
RCPH10TLB694ABL 41
53. Repeat steps 47 through 51 for the opposite end of

the axle.
54. See specifications for the correct lubricant for the
center bowl.
55. Lubricate the king pins with molydisulfide grease.
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Differential - Remove - Carraro Front axle-four wheel drive

differential carrier- 580SN-WT and 590SN only
1. Drain the lubricant from the center bowl.
2. Loosen but do not remove the nut.
RCPH10TLB482ABL 1
3. Use an acceptable puller to loosen the ball joint.
RCPH10TLB483ABL 2
RCPH10TLB484ABL 3
5. Fasten suitable lifting equipment as shown and re-

move the bolts from the top king pin. Use acceptable
tools and remove the top king pin.
RCPH10TLB711ABL 4
47365539 08/07/2012
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6. Remove the bolts and use acceptable tools to re-

move the bottom king pin.
RCPH10TLB500ABL 5
7. Remove the planetary and axle assembly.
RCPH10TLB712ABL 6

axle.
9. Use tool 38010092 and remove the right tie rod.
RCPH10TLB502ABL 7
10. Remove the fitting from the closed end of the steering
cylinder.
RCPH10TLB505ABL 8
47365539 08/07/2012
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12. Use a soft-faced hammer to remove the steering

cylinder.
RCPH10TLB506ABL 9
RCPH10TLB508ABL 10

ential carrier.
RCPH10TLB509ABL 11
Next operation:
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Differential - Disassemble - Carraro Front axle-four wheel drive

1. Fasten the differential carrier in a repair stand.
RCPH10TLB462ABL 1

RCPH10TLB701ABL 2

leg on the ring gear side of the differential carrier.
RCPH10TLB702ABL 3
4. Remove the bolt and lock that hold each adjusting

ring.
RCPH10TLB703ABL 4
47365539 08/07/2012
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RCPH10TLB704ABL 5
6. Loosen both adjusting rings.
RCPH10TLB715ABL 6
7. Remove the 4 bolts. Use a soft-faced hammer to

loosen the 2 bearing caps.
RCPH10TLB706ABL 7
8. Remove the adjusting rings, bearing cups, and dif-

ferential.
RCPH10TLB707ABL 8

installation.
47365539 08/07/2012
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RCPH10TLB511ABL 9
11. Use a narrow chisel to push the nut out of the pinion
shaft.
RCPH10TLB512ABL 10
12. Use the yoke and CAS-2151 tool to remove the pin-
ion nut.
RCPH10TLB471ABL 11
RCPH10TLB529ABL 12
47365539 08/07/2012
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14. Use a soft hammer and drive the pinion shaft out of
the outer bearing.
RCPH10TLB530ABL 13
15. Remove the flat washers and spacer. Discard the

spacer. The spacer MUST NOT be used again.
RCPH10TLB533ABL 14
RCPH10TLB534ABL 15
17. Remove the shim.
RCPH10TLB535ABL 16
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18. Remove the bearing cups only if inspection indicates

the need for new parts.
RCPH10TLB531ABL 17
19. Use an acceptable puller and remove the seal form

the cover.
RCPH10TLB713ABL 18
RCPH10TLB691ABL 19
Next operation:
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Differential - Disassemble - Carraro Front axle-four wheel drive -

differential - 580SN-WT and 590SN only
RCPH10TLB513ABL 1
RCPH10TLB514ABL 2
3. Separate the case halves.
RCPH10TLB515ABL 3
4. Remove the thrust washer and side gear.
RCPH10TLB516ABL 4
47365539 08/07/2012
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RCPH10TLB518ABL 5
RCPH10TLB520ABL 6
RCPH10TLB521ABL 7
NOTE: Steps 8 through 10 are for limited slip differentials.

RCPH10TLB632ABL 8
47365539 08/07/2012
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RCPH10TLB631ABL 9
10. Remove the reaction and friction plates.
RCPH10TLB630ABL 10
NOTE: The plate at the side gear must be kept in that position.
11. Remove and install new bushings in the case halves
as required.
RCPH10TLB522ABL 11
12. Remove the bearing from either case half as shown.
RCPH10TLB463ABL 12
Next operation:
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Differential - Inspect - Carraro Front axle-four wheel drive -

2. Inspect the bearing cup and the rollers in the bear-
ings for flat areas, pitting, scoring, and other dam-
age. Also check the inner race for damage. If any of
these defects are found, a new bearing and bearing
cup must be installed.
4. Inspect the side gears, the pinion shaft and the teeth
of the pinion gears for pitting, scoring, and other dam-
each pinion gear. Check the splines in the side gears
for wear. Use new parts as required.
6. Limited slip differentials, check reaction and friction
plates for discoloration, scarring and chipping. Mea-
sure thickness of friction and separator plates, use
new parts as required.
NOTICE: 1. Separator plate new 1.5 +- 0.03MM. (0.059+- 0.001 IN) minimum thickness 1.4 MM (0.055 IN). 2. Friction
plate new 1.6 +- 0.03 MM. (0.063 +- 0.001 IN) minimum thickness 1.45MM. (0.057 IN). 3. Friction plate new 2.8 +-
0.03 MM. (0.11 +- 0.001 IN) minimum thickness 2.7 MM. (0.10 IN).
Next operation:
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Differential - Assemble - Carraro Front axle-four wheel drive -

1. Use the CAS-2395 and press a new bearing onto
each case half.
RCPH10TLB463ABL 1
2. Find the case half that has the threaded holes. Make
sure that the threads are free of lubricant.
RCPH10TLB523ABL 2
3. Lubricate the thrust washers, pinion gears and pinion

shaft with gear lubricant.
RCPH10TLB524ABL 3
NOTE: Step 4 through 7 pertain to the limited slip differential.

4. Lubricate and place a reaction plate in the case half.
RCPH10TLB629ABL 4
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5. Lubricate and place a friction plate in the case half,

alter reaction and friction plates until five reaction and
four friction plates are inside the case half.
RCPH10TLB628ABL 5
6. Lubricate and place the side gear friction plate on the

side gear.
RCPH10TLB627ABL 6
7. Work the side gear in a rotating motion until the gear

has engaged all of the friction plates.
RCPH10TLB632ABL 7
NOTE: Repeat steps 4 through 7 for the other case half.

8. Install a thrust washer in the case half that has
threaded holes.
RCPH10TLB521ABL 8
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9. Install a side gear.
RCPH10TLB520ABL 9
10. Install the thrust washers and pinion gears on the

pinion shaft.
RCPH10TLB525ABL 10
RCPH10TLB519ABL 11
12. Install the pinion shaft assembly.
RCPH10TLB518ABL 12
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13. Apply Loctite to the threads in the case half.
RCPH10TLB526ABL 13
14. Install the other side gear.
RCPH10TLB517ABL 14
15. Install the other thrust washer in the other case half.
RCPH10TLB527ABL 15
16. Using the two reference marks on the case halves,

assemble the two case halves.
RCPH10TLB515ABL 16
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17. Make sure that the mounting surfaces for the ring
gear are clean and install the ring gear.
RCPH10TLB514ABL 17
18. Use the press to prevent the differential from turning

and install and tighten the bolts to: 580SN - WT -
95 Nm (70 pound-feet), 590SN - 120 Nm (88 pound-
feet).
RCPH10TLB528ABL 18
Next operation:
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Differential - Assemble - Carraro Front axle-four wheel drive

1. Use a soft-faced hammer and a suitable driver and
drive the bearing cup(s) into the differential carrier.
RCPH10TLB532ABL 1
2. Assemble the gauge block, pilot and stud from the

CAS-1839 pinion setting kit.
3. Install the gauge block, pilot, bearings and handle.
See special tools. Tighten the handle until the bear-
ings become difficult to turn.
RCPH10TLB537ABL 2
4. Install the gauge tube and bearing caps with marks

aligned.
RCPH10TLB538ABL 3
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5. Tighten the bolts to 156 Nm (115 pound-feet).
RCPH10TLB539ABL 4

between the gauge black and the gauge tube. Write
the measurement on line "b" in step 8.
RCPH10TLB540ABL 5
NOTE: The pinion gear shown is for a Powershift transmission. The helix spiral is opposite of the Carraro pinion gear.
The procedure is the same.
7. Write the number on the end of the pinion shaft on
line "d" in step 8.
RCPH10TLB458ABL 6
8. The number on line "A" does not change. Add line

"A" and line "B" and write the answer on line "C".
Subtract line "D" from line "C" and write the answer
on line "E". Line "E" is the thickness of the shim to
be installed on the pinion shaft. Use 2.75 MM thick
shim.
A. 109.75 MM A. 109.75 MM
B. MM B. +0.45 MM
C. MM C. 110.20 MM
D. MM D. -107.45 MM
E. MM E. 2.75 MM
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9. Remove the bolts, bearing caps, gauge tube, handle,

gauge block assembly and the bearings.
RCPH10TLB541ABL 7
10. Install the shim with the thickness specified in step 8.

The chamfer on the ID of the shim must be towards
the pinion gear.
RCPH10TLB535ABL 8
11. Use the CAS-2370 inner/outer pinion bearing cone

installer and press the inner bearing against the
shim.
RCPH10TLB536ABL 9
RCPH10TLB542ABL 10
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13. Install a new spacer and flat washers. The old spacer
MUST NOT be used again.
RCPH10TLB533ABL 11
RCPH10TLB543ABL 12
RCPH10TLB544ABL 13
RCPH10TLB545ABL 14
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17. Use the yoke and the CAS-2151A wrench and

tighten the pinion nut to 68 Nm (50 pound-feet).
RCPH10TLB470ABL 15

bearings become seated.
NOTE: If the pinion nut is tightened too much (rotating
torque more than specified), the pinion will have to be re-
moved and a new spacer installed on the pinion shaft.
19. The art shows a socket being used. Use the
CAS-2375 and a pound-inch torque wrench to
check the rotating torque of the pinion shaft. The
rotating torque must be 1.7 to 2.2 Nm (15 to 20
pound-inches). If the rotating torque is less than
specified, tighten the pinion nut a SMALL amount
and check the rotating torque again.
RCPH10TLB546ABL 16
20. When the rotating torque is as specified, use a soft-

faced hammer and punch and drive part of the pinion
nut into the slot in the pinion shaft.
RCPH10TLB547ABL 17
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RCPH10TLB691ABL 18
22. Use a soft-faced hammer and a suitable driver and

drive a new seal into the cover.
RCPH10TLB714ABL 19
23. Put the CAS-2369 seal protector on the pinion shaft.
RCPH10TLB709ABL 20
stall the cover.
RCPH10TLB710ABL 21
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RCPH10TLB548ABL 22
26. Install the bearing cups.
RCPH10TLB549ABL 23
27. Install the bearing caps.
RCPH10TLB550ABL 24
NOTE: Align marks made during disassembly.

28. Tighten the bolts to pull the bearing caps against then
bearings must be able to rotate.
RCPH10TLB551ABL 25
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29. Install the adjusting rings.
RCPH10TLB552ABL 26
30. Use the CAS-1840C and tighten both adjusting rings

while making sure that there is clearance (backlash)
between the ring gear and pinion gear.
RCPH10TLB553ABL 27
31. Use a dial indicator and check for end play.
RCPH10TLB555ABL 28
32. If there is end play, tighten the adjusting ring on the

tooth side of the ring gear until there is no end play.
33. If there is no end play, loosen the adjusting ring on the
back face side of the ring gear to make sure that there
is clearance between the ring gear and pinion gear
and tighten the opposite adjusting ring until there is
no end play.
34. When there is no end play, tighten each adjusting
ring one notch.
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35. Use the dial indicator and check the backlash for the
ring gear at 90 degree intervals. If the readings are
not equal, adjust the backlash at the position that had
the smallest reading.
RCPH10TLB510ABL 29
used, the backlash must be equal to the measure-
37. If a new ring and pinion gear are being used, the
backlash must be 0.20 to 0.25 mm (0.008 to 0.010
inch).
38. If there is not enough backlash, use the CAS-1840C
and loosen the adjusting ring on the backface side
of the ring gear one notch and tighten the opposite
adjusting ring one notch. Check the backlash again.
Continue with this step until the backlash is correct.
RCPH10TLB556ABL 30
39. If there is too much backlash, use the CAS-1840C

and loosen the adjusting ring on the tooth side of the
ring gear one notch and tighten the opposite adjust-
ing ring one notch. Check the backlash again. Con-
tinue with this step until the backlash is correct.
RCPH10TLB557ABL 31
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RCPH10TLB554ABL 32
41. Install the lock, bolt and lock washer that hold each
adjusting ring. Tighten the bolts to 13 Nm (120
pound-inches).
RCPH10TLB558ABL 33
42. Apply Loctite 510
RCPH10TLB559ABL 34
RCPH10TLB560ABL 35
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feet).
RCPH10TLB508ABL 36
45. Install the steering cylinder.
RCPH10TLB507ABL 37
46. Install and tighten the bolts to 120 Nm (88.5 pound -

feet).
RCPH10TLB504ABL 38
47. Install and tighten the tie rod using the 38010092 to
a torque of 300 Nm (222 pound-feet).
RCPH10TLB503ABL 39
48. Install and tighten the fitting at the closed end of the
steering cylinder.
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49. Install the planetary and axle assembly. It may be

necessary to have another person turn the pinion
shaft.
RCPH10TLB712ABL 40
50. Install the top king pin, belville washer, spacer, blots
and lock washers. Tighten the bolts to a torque of
190 Nm (140 pound-feet).
RCPH10TLB501ABL 41
51. Install the bottom king pin, belville washer, bolts and
lock washers. Tighten the bolts to a torque of 190
52. Install the ball joint and nut. Tighten the nut to
a torque of 165 Nm (122 pound-feet) for the 580
SN-WT and 220 Nm (162 pound-feet) for the 590
SN.
53. Repeat steps 47 through 51 for the opposite end of
the axle.
54. Fill the center bowl. Refer to the specifications.
55. Lubricate the king pins with molydisulfide grease.
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Index

Differential - Assemble - CNH Front Axle - Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Differential - Assemble - CNH Front Axle - Four Wheel Drive - Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Differential - Assemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . 46
Differential - Assemble - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . 74
Differential - Assemble - Carraro Front axle-four wheel drive differential carrier- 580N and 580SN only . . . . . . . 50
Differential - Assemble - Carraro Front axle-four wheel drive differential carrier- 580SN-WT and 590SN only . . 79
Differential - Disassemble - CNH Front Axle -Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Differential - Disassemble - CNH Front Axle -Four Wheel Drive- Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . 14
Differential - Disassemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . 42
Differential - Disassemble - Carraro Front axle-four wheel drive - differential - 580SN-WT and 590SN only . . . . 70
Differential - Disassemble - Carraro Front axle-four wheel drive differential carrier- 580N and 580SN only . . . . . 37
Differential - Disassemble - Carraro Front axle-four wheel drive differential carrier- 580SN-WT and 590SN only 65
Differential - Exploded view - CNH- Front Axle - Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Differential - Exploded view - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . 4
Differential - Exploded view - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . 6
Differential - Exploded view - Carraro Front axle-four wheel drive limited slip differential- 580SN-WT and 590SN
only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Differential - Inspect - CNH Front Axle - Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Differential - Inspect - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . 45
Differential - Inspect - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . 73
Differential - Remove - CNH Front Axle -Four Wheel Drive - Differential Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Differential - Remove - Carraro Front axle-four wheel drive differential carrier- 580N and 580SN only . . . . . . . . . 34
Differential - Remove - Carraro Front axle-four wheel drive differential carrier- 580SN-WT and 590SN only . . . . 62
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Final drive hub, steering knuckles, and shafts - 108
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Planetary drive and hub

Exploded view - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view - Carraro Front axle-four wheel drive - 580SN-WT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view - Carraro Front axle-four wheel drive - 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exploded view - CNH Front Axle - Planetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE
Planetary drive and hub

Disassemble - CNH Front Axle Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspect - CNH Front Axle Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assemble - CNH Front Axle Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . 29
Inspect - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Assemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Disassemble - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . 42
Inspect - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . 50
Assemble - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . 51
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Front axle system - Final drive hub, steering knuckles, and shafts
Planetary drive and hub - Exploded view - Carraro Front axle-four

wheel drive - 580N and 580SN only
1. Seal 11. Thrust washer
2. Wheel bearing 12. Snap ring
3. Bearing cup 13. Retainer
4. Planetary housing 14. Pinion gear
5. Stud 15. Pin
6. Retaining ring 16. O-ring
7. Hub 17. Carrier
8. Bolt 18. Allen head bolt
9. Ring gear 19. Pinion shaft
10. Thrust plate 20. Bushing
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RCPH10TLB001HAL 1
47365539 08/07/2012
25.108 / 5

wheel drive - 580SN-WT
1. Axle shaft 16. Snap ring
2. Seal 17. Retainer
3. Bearing assembly 18. Pinion gear
4. Planetary housing 19. Needles
5. Stud 20. O-ring
6. Bearing assembly 21. Allen head bolt
7. Retaining ring 22. Carrier
8. Hub 23. Pinion shaft
9. Ring gear 24. Plug
10. Bolt 25. O-ring
11. Bushing 26. Nut
12. Snap ring 27. Washer
13. Thrust plate 28. Pin
14. Thrust plate 29. Thrust washer
15. Thrust washer
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RCPH10TLB002GAL 1
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25.108 / 7

wheel drive - 590SN
1. Seal 11. Bushing
2. Bearing assembly 12. Needles
3. Planetary housing 13. Plug
4. Stud 14. Allen head bolt
5. O-ring 15. Carrier
6. Bearing assembly 16. Thrust button
7. Retaining ring 17. Pinion shaft
8. Hub 18. Pinion gear
9. Ring gear 19. Retainer
10. Bolt 20. Snap ring
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RCPH10TLB003GAL 1
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Planetary drive and hub - Exploded view - CNH Front Axle -

Planetary
Planetary
1. Drain Plug 6. Planet pinion gear 11. Ring gear 16. Stud
w/needles
2. Drain Plug O-ring 7. Retainers 12. Hub 17. Seal
3. Allen head bolts 8. Bolts 13. Retaining ring
4. Planetary Carrier 9. T-dowels 14. Wheel Bearing
5. O-ring 10. Pinion nut 15. Wheel hub
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RCPH10TLB180GAL 1
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Planetary drive and hub - Disassemble - CNH Front Axle Four

Wheel Drive
Prior operation:
1. See planetary exploded view: Planetary drive and

hub - Exploded view (25.108)
NOTE: The following procedures show the axle already removed from the machine for ease of explanation.
2. Raise the wheel(s) off the floor and use acceptable
supports to hold the machine in position.
3. Remove the nuts and hardened washers and re-
move the wheel(s). Powered front axle - Remove
(25.100)
4. Drain the oil.
RCPH10TLB276ACL 1
5. Remove the two Allen head bolts 6mm that hold the
carrier.
RCPH10TLB946ABL 2
6. Separate the carrier from the planetary housing us-

ing the 2 prybar slots.
RCPH10TLB277ACL 3
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25.108 / 12
Planetary Carrier
7. Remove the carrier from the planetary housing.
RCPH10TLB947ABL 4
NOTE: Take care when removing the cover. Pull the cover evenly on both sides to prevent gear damage. Capture
and discard residual oil from the cover.
8. Discard the O-ring.
RCPH10TLB275ACL 5
NOTE: Hub seal should be replaced.

9. Loosen 3 retaining screws 8 mm.
RCPH10TLB292ACL 6
NOTE: Use a hand wrench, not impact gun to avoid gear damage. Use care to avoid stripping socket in bolt head.
Replace bolt if needed. Easy out size 11/32" is effective for stripped bolt head hex sockets.
47365539 08/07/2012
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10. Mark retainers, gears and pins.
RCPH10TLB360ACL 7
11. Remove retainers.
RCPH10TLB361ACL 8
12. Inspect retainers for dents or damage in roller contact

area.
RCPH10TLB362ACL 9
NOTE: Visually inspect. Also, inspect by running finger around the outer edge of the lower surface. Any detected
dents or damage will require rework to polish off rough edges.
13. During inspection, the use of a magnifying glass is
recommended.
RCPH10TLB363ACL 10
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25.108 / 14
14. Any dent or rough edge that can be felt or seen must
be reworked.
RCPH10TLB364ACL 11
15. Example of an unacceptable dent in the bearing con-

tact area.
RCPH10TLB365ACL 12
16. For slight damage rework retainer using 400 grit

sandpaper, as shown or replace, as required.
RCPH10TLB366ACL 13
17. Example of reworked retainer with the bearing con-

tact area removed.
RCPH10TLB367ACL 14
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25.108 / 15
18. Remove gear, as necessary. and place rollers into

individual containers for possible reuse.
RCPH10TLB360ACL 15
NOTE: . The drain plug has a powerful magnet. The technician may choose to cover the magnet with a rag, tape or
cardboard to allow rollers to be more easily removed from the carrier.
19. Ensure all rollers have been removed and wipe off
any contamination on the drain plug.
RCPH10TLB369ACL 16
NOTE: Thoroughly inspect entire carrier for rollers, including inside the threaded holes in the gear pins.
Hub
20. Use acceptable tools to loosen the crimping on the
nut.
RCPH10TLB279ACL 17
NOTE: Use a very narrow chisel/round end punch to unstake the nut. to avoid gear damage.
47365539 08/07/2012
25.108 / 16
21. Loosen nut. Use a 55mm socket or special tool

380000468.
RCPH10TLB961ABL 18
22. Remove the nut.
RCPH10TLB281ACL 19
23. Remove the bolts for the hub The axle will have either
10 bolts (M10) or 8 bolts (M12).
RCPH10TLB282ACL 20
24. Install two bolts in the two threaded holes in the hub.
Tighten the two bolts evenly until the ring gear is free
of the swivel housing. Use 2 bolts removed from step
22.
RCPH10TLB284ACL 21
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25.108 / 17
25. Remove the ring gear assembly. See section Axle

housing - Disassemble (25.100) for knuckle re-
moval.
RCPH10TLB285ACL 22
NOTE: Ensure you slide the axle shaft from the swivel housing assembly.
26. If necessary, remove the retaining ring which fastens
the hub in the ring gear.
RCPH10TLB289ACL 23
27. Separate the hub and ring gear.
RCPH10TLB290ACL 24
28. Press the T-dowels from the hub and discard.
RCPH10TLB625ABL 25
NOTE: Manufacturer recommends replacement of T-dowels if they are pressed out of the hub.
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29. Use an acceptable puller to remove the wheel hub

assembly from the swivel housing.
RCPH10TLB299ACL 26
30. Remove the outer wheel bearing.
RCPH10TLB300ACL 27
31. Remove the wheel hub assembly.
RCPH10TLB301ACL 28
32. Remove the cassette seal and bearing cups, as nec-

essary.
RCPH10TLB302ACL 29
NOTE: Cassette seal must be replaced. Replace bearing cups as necessary.
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25.108 / 19
33. Remove the wheel bearing from the swivel housing,

if necessary.
RCPH10TLB400ACL 30
34. Remove the axle shaft seal.
RCPH10TLB401ACL 31
RCPH10TLB261ACL 32
36. Remove axle shaft ball bearing.
RCPH10TLB260ACL 33
Next operation:
Planetary drive and hub - Inspect (25.108)
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Planetary drive and hub - Inspect - CNH Front Axle Four Wheel Drive
2. Inspect all bearing assemblies for flat areas, pitting,
scoring, and other damage. Also check the races for
damage. If any of these defects are found, a new
wheel bearing and bearing cup must be installed.
3. Inspect the planetary shafts for wear and damage.
4. Inspect the teeth of the planet gears, sun gear and
ring gear for wear, pitting, scoring, and other dam-
age. Use new parts as required.
Next operation:
Planetary drive and hub - Assemble (25.108)
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Planetary drive and hub - Assemble - CNH Front Axle Four Wheel
Drive
Planetary Carrier
1. Install planetary gear over installation tool
DMT100002
RCPH10TLB370ACL 1
2. Insert rollers between installation assembly tool and

gear as shown. Apply petroleum jelly to help retain
rollers.
RCPH10TLB371ACL 2
3. Ensure all rollers are installed.
RCPH10TLB372ACL 3
4. Install gears on the same pin they were removed

from using marks as a guide.
RCPH10TLB374ACL 4
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25.108 / 22
5. Push roller installation tool (DMT100002) off of gear

as gear & rollers engage pin.
RCPH10TLB375ACL 5
6. Confirm all lower rollers are properly installed. After

all 3 gears are installed, confirm all lower rollers are
properly installed. After all 3 gears are installed, re-
orient planetary carrier horizontally.
RCPH10TLB376ACL 6
7. Install upper rollers into gears, as shown. Ensure all

rollers are installed.
RCPH10TLB402ACL 7
8. Where possible align retainers with the original pin

using the marks applied previously. Align dowel with
offset hole on retainer.
RCPH10TLB378ACL 8
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25.108 / 23
9. Use an 8mm allen wrench and tighten. Use torque

wrench Do not use an impact gun.
RCPH10TLB380ACL 9
NOTE: Apply 3 drops of Loctite 242.

10. Tighten to 95 - 105 N·m (70.1 - 77.4 lb ft)
NOTE: Apply approximately 5 drops of MS1317 oil at top of all rollers. Ensure gear has free end play by moving it up
and down. Should be approximately 1 mm play. Spin each gear to make sure they are free to rotate.
11. If bearing cups were removed, use an acceptable
driver to press new bearing cups into the planetary
housing. Special Tool DMT100004
RCPH10TLB578ABL 10
12. The words "OUTSIDE" on the seal must be facing

up. Use hub seal installation tool (DMT100004) to
drive the new seal into the wheel hub. . Use the
flat side of the hub seal installer. Do not damage
the seal. Lightly coat outside diameter of seal with
Kluberplus.. Depth: 580N & 580SN 1.5 mm (0.059
in), 580SN-WT & 590SN 6.5 mm (0.256 in)
RCPH10TLB622ABL 11
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25.108 / 24
13. Install two new T-dowels 180 degrees apart such that
they protrude 4 mm (0.157 in).
RCPH10TLB626ABL 12
14. Install the hub to the ring gear.
RCPH10TLB624ABL 13
15. Install the retaining ring. Ensure it is fully seated into

the groove.
RCPH10TLB998ABL 14
16. Install inner wheel bearing.
RCPH10TLB400ACL 15
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17. Install the hub. Use a press to pshl hub on evenly

and square to ensure proper seal seating. Seal ID
must have light coat of Kluberplus.
RCPH10TLB387ACL 16
18. Install a wheel bearing on the swivel housing. In-

stallation will be easier if you heat the wheel bearing
slightly. Do not heat the wheel bearing higher than
149 °C (300.2 °F). Use clean gear lubricant to lubri-
cate the wheel bearing.
RCPH10TLB388ACL 17
19. Install the axle shaft bearing. Install snap ring. Install
axle shaft seal to a depth of 6.1 mm (0.240 in).
RCPH10TLB261ACL 18
NOTE: Ensure proper seating of snap ring into groove.

20. Align the two bushings with two of the holes on the
swivel housing, then simultaneously press the heads
of the bushings to install the ring gear assembly.
RCPH10TLB285ACL 19
21. Press remaining T- dowels into place 2 at a time 180

degrees apart.
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22. Apply Loctite to bolts . Instal bolts l and tighten evenly

to pull the ring gear assembly against the swivel
housing. Tighten the bolts in a star pattern to a final
torque of: 580N & 580SN 55 - 68 N·m (40.6 - 50.2
lb ft) and 580SN-WT & 590SN 96 - 118 N·m (70.8 -
87.0 lb ft).
RCPH10TLB282ACL 20
NOTE: Tighten bolts in a star pattern. Rotate hub while tightening bolts to avoid damage to wheel bearings.
23. Install the nut. Use 3 to 4 drops of Loctite 242.
Tighten to 358 - 442 N·m (264.0 - 326.0 lb ft). Use
special tool 380000468 to tighten. Stake the nut in 2
places approximately 180 degrees apart.
RCPH10TLB961ABL 21
NOTE: Nut staking material should be crimped and not cracked or torn. Ensure opposite side of shaft is secure while
tightening nut.
24. Install a new O-ring on the planetary carrier.
RCPH10TLB275ACL 22
NOTE: Lubricate O-ring with oil prior to installation

25. Install the planetary carrier. Hold planetary carrier in
a level position. Do not force, it may be necessary to
turn input pinion.
RCPH10TLB947ABL 23
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26. Install and tighten the two Allen head bolts to a torque
of 21 - 26 N·m (15.5 - 19.2 lb ft)
RCPH10TLB945ABL 24
27. Lubricate the planetary Powered front axle - Gen-

eral specification (25.100)
28. Install the wheel(s), hardened washers, and nuts.
Powered front axle - Install (25.100) Tighten the
nuts. Powered front axle - Install (25.100)
47365539 08/07/2012
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Planetary drive and hub - Disassemble - Carraro Front axle-four

wheel drive - 580N and 580SN only
2. Remove the nuts and hardened washers and remove
the wheel(s). Drain the oil from the carrier.
3. Remove the two Allen head bolts that hold the carrier.
RCPH10TLB561ABL 1
4. Separate the carrier from the planetary housing.
RCPH10TLB562ABL 2
5. Remove the carrier.
RCPH10TLB563ABL 3
47365539 08/07/2012
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RCPH10TLB564ABL 4
7. Remove the thrust washer with the internal tabs.
RCPH10TLB565ABL 5
8. Remove the thrust plate with the external tabs.
RCPH10TLB566ABL 6
9. Remove the bolts for the hub.
RCPH10TLB567ABL 7
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10. Install two 10mm. bolts in the two threaded holes in

the hub. Tighten the two bolts evenly until the ring
gear is free of the swivel housing.
RCPH10TLB568ABL 8
RCPH10TLB569ABL 9
12. Use an acceptable puller to remove the outer wheel

bearing from the swivel housing.
RCPH10TLB570ABL 10
13. Remove the planetary housing and the wheel bear-

ing.
RCPH10TLB571ABL 11
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14. Use prybars to remove the inner wheel bearing from

the swivel housing. Be careful so that you do not
damage the inner wheel bearing.
RCPH10TLB572ABL 12
15. Remove the retaining ring which fastens the hub in

the ring gear.
RCPH10TLB660ABL 13
16. Remove the hub.
RCPH10TLB624ABL 14
17. Press the bushings from the hub only if new bush-
ing(s) are needed or a new hub is installed.
RCPH10TLB625ABL 15
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18. Remove the snap rings.
RCPH10TLB573ABL 16
19. Remove the retainer.
RCPH10TLB574ABL 17
20. Remove the pinion gears and thrust washers. Be

careful so that you do not lose the needles.
RCPH10TLB575ABL 18
21. Press the pinion shafts out of the carrier.
RCPH10TLB576ABL 19
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22. Remove the bearing cups and the seal as necessary.
RCPH10TLB577ABL 20
Next operation:
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Planetary drive and hub - Inspect - Carraro Front axle-four wheel

drive - 580N and 580SN only
Refer to Planetary drive and hub - Exploded view
(25.108) for more details
1. Clean all parts with cleaning solvent.
2. Inspect the bearing cup and the rollers in the wheel
bearings for flat areas, pitting, scoring, and other
damage. Also check the inner face for damage. If
any of these defects are found, a new wheel bearing
and bearing cup must be installed.
3. Inspect the pinion shafts for wear and damage.
4. Inspect the teeth of the pinion gears, the axle shafts,
and the ring gear for wear, pitting, scoring, and other
damage. Use new parts as required.
5. Inspect the needles for the pinion gears for flat areas,
pitting, scoring, and other damage. If any of these
defects are found, also inspect the bore of the pinion
gears and use new parts as required.
6. Inspect the thrust washer for the axle shaft in the bore
in the carrier. Do not remove the thrust washer un-
less there is wear or damage. The thrust washer is
held in position with adhesive. If replacement is nec-
essary, use B500621 kit (324 Loctite and 707 Activa-
tor) to install the new thrust washer. Use the instruc-
tions on the container. Curing time is approximately
five minutes.
Next operation:
47365539 08/07/2012
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Planetary drive and hub - Assemble - Carraro Front axle-four wheel

drive - 580N and 580SN only
1. If bearing cups were removed, use an acceptable
driver to press new bearing cups into the planetary
housing.
RCPH10TLB578ABL 1
2. The words “OUTSIDE” on the seal must be facing

up. Use the CAS2374A to drive the new seal into
the planetary housing. Use the flat side of the Hub
Seal Installer. Be careful not to damage the seal.
RCPH10TLB622ABL 2
3. Press the pinion shafts into the carrier until the inner
end of the pinion shafts are 34.3 to 36.8 MM. (1.350
to 1.450 inch) from the machined surface on the car-
rier.
4. Apply petroleum jelly to one side and the bore of the
pinion gears.
RCPH10TLB479ABL 3
47365539 08/07/2012
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5. Install a thrust washer.
RCPH10TLB480ABL 4
6. Install 30 needles in each pinion gear using petro-

leum jelly to hold the needles in place.
RCPH10TLB481ABL 5
7. Install the pinion gears so that each thrust washer is

toward the carrier.
RCPH10TLB575ABL 6
8. Install the retainer.
RCPH10TLB574ABL 7
47365539 08/07/2012
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9. Install the snap rings.
RCPH10TLB573ABL 8
10. Press bushings into the hub as required.
RCPH10TLB626ABL 9
11. Install the hub.
RCPH10TLB624ABL 10
RCPH10TLB623ABL 11
47365539 08/07/2012
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13. Install a wheel bearing on the swivel housing. In-

stallation will be easier if you heat the wheel bearing
slightly. Do not heat the wheel bearing higher than
149° C (300° F). Use clean gear lubricant to lubri-
cate the wheel bearing.
RCPH10TLB579ABL 12
14. Install the planetary housing.
RCPH10TLB580ABL 13
15. Install the outer wheel bearing. Installation will be

Install the thrust plate with the external tabs. easier
if you heat the wheel bearing slightly. Do not heat the
wheel bearing higher than 149° C (300° F).
RCPH10TLB581ABL 14
16. Align the holes in the hub with the holes in the swivel
housing and install the ring gear.
RCPH10TLB582ABL 15
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17. Put 270 Loctite in the female threads in the swivel

housing. Install and tighten the bolts evenly to pull
the hub against the swivel housing. Tighten the bolts
to a final torque of 95 Nm (70 pound-feet).
RCPH10TLB567ABL 16
18. Install the thrust plate with the external tabs.
RCPH10TLB566ABL 17
19. Install the thrust washer with the internal tabs.
RCPH10TLB565ABL 18
RCPH10TLB564ABL 19
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21. Install a new O-ring on the planetary housing.
RCPH10TLB583ABL 20
22. Install the carrier.
RCPH10TLB584ABL 21
23. Install and tighten the Allen head bolts to a torque of

25 Nm (19 pound-feet).
RCPH10TLB561ABL 22
24. See Specifications for the correct lubricant for the

planetary.
25. Install the wheel(s), hardened washers, and nuts.
Tighten the nuts to specifications.
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Planetary drive and hub - Disassemble - Carraro Front axle-four

wheel drive - 580SN-WT and 590SN only
support to hold the machine in position.
2. Remove the nuts and hardened washers and remove
the wheel(s).
3. Remove the drain plug from the carrier.
RCPH10TLB642ABL 1
4. Drain the oil from the carrier.
RCPH10TLB641ABL 2
5. Remove the two allen head bolts that hold the carrier.
RCPH10TLB643ABL 3
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6. Use a soft-faced hammer to separate the carrier from

the planetary housing.
RCPH10TLB645ABL 4
7. Remove the carrier.
RCPH10TLB646ABL 5
8. Discard O-ring.
RCPH10TLB680ABL 6
RCPH10TLB647ABL 7
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10. Remove the thrust washer with the internal tabs.
RCPH10TLB648ABL 8
11. Remove the thrust washer with the external tabs.
RCPH10TLB649ABL 9
12. Remove the bolts from the hub.
RCPH10TLB650ABL 10
13. Use two bolts that were removed from the hub and
install them in the two threaded holes in the hub.
Tighten the bolts evenly until the ring gear is free of
the wheel hub.
RCPH10TLB652ABL 11
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RCPH10TLB653ABL 12
15. Use an acceptable puller to remove the outer wheel

bearing from the wheel hub.
RCPH10TLB654ABL 13
16. Remove the wheel bearing.
RCPH10TLB655ABL 14
17. Remove the planetary housing from the wheel hub.
RCPH10TLB656ABL 15
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18. Use prybars to remove the inner wheel bearing form

the swivel housing. Be careful so that you do not
damage the inner wheel bearing.
RCPH10TLB657ABL 16
19. Remove the retaining ring.
RCPH10TLB660ABL 17
20. Remove the hub.
RCPH10TLB662ABL 18
21. Press the busings from the hub only if new bushing(s)
are needed or a new hub is installed.
RCPH10TLB670ABL 19
NOTE: Steps 22 through 24 is for the 580SN-WT
47365539 08/07/2012
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22. Remove the snap rings securing the retaining plate.
RCPH10TLB688ABL 20
RCPH10TLB689ABL 21
24. Remove the pinion gears and thrust washers. Be

careful so that you do not lose the needles.
RCPH10TLB690ABL 22
NOTE: Steps 25 through 27 are for the 590 SN.

25. Remove the snap rings from the pinion gears.
RCPH10TLB665ABL 23
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26. Remove the retainer.
RCPH10TLB664ABL 24
27. Remove the pinion gears being careful not to lose

the needles.
RCPH10TLB669ABL 25
28. Press the pinion shafts out of the carrier if new ones
are to be installed.
RCPH10TLB672ABL 26
29. Remove the bearing cups and seal as required.
RCPH10TLB674ABL 27
Next operation:
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Planetary drive and hub - Inspect - Carraro Front axle-four wheel

drive - 580SN-WT and 590SN only
2. Inspect the bearing cup and the rollers in the wheel
damage. Also check the inner race for damage. If
any of these defects are found, a new wheel bearing
and bearing cup must be installed.
3. Inspect the pinion shafts for wear and damage.
4. Inspect the teeth of the pinion gears, the sun gear,
and the ring gear for wear, pitting, scoring, and other
damage. Use new parts as required.
5. Inspect the needles for the pinion gears for flat areas,
pitting, scoring and other damage. If any of these
defects are found, also inspect the bore of the pinion
gears and use new parts as required.
6. Inspect the thrust washer for the axle shaft in the bore
in the carrier. Do not remove the thrust washer un-
less there is wear or damage. The thrust washer is
held in position with adhesive. If replacement is nec-
essary, use B500621 kit (324 Loctite and 707 Activa-
tor) to install the new thrust washer. Use the instruc-
tions on the container. Curing time is approximately
five minutes.
Next operation:
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Planetary drive and hub - Assemble - Carraro Front axle-four wheel

drive - 580SN-WT and 590SN only
1. If bearing cups were removed, use a suitable driver
to press new bearing cups into the wheel hub.
2. Clean hub prior to seal installation
RCPH10TLB682ABL 1
3. The lip on the seal must be facing in towards bearing.
RCPH10TLB675ABL 2
4. Use seal driver 380002431 to drive the new seal into

the wheel hub. Be careful not to damage the seal.
RCPH10TLB673ABL 3
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5. If the pinion shafts were removed, use acceptable

tools to press the pinion shafts into the carrier until
the inner end of the pinion shafts are 34.3 to 36.8
mm (1.350 to 1.450 inch) from the machined surface
on the carrier.
RCPH10TLB676ABL 4
NOTE: Steps 1 through 10 are for the 580SN-WT.

6. Apply petroleum jelly to one side of the bore of the
pinion gears.
RCPH10TLB685ABL 5
7. Install a thrust washer.
RCPH10TLB686ABL 6
8. Install 30 needles in each pinion gear using petro-

leum to hold the needles in place.
RCPH10TLB687ABL 7
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9. Install the pinion gears so that each thrust washer is

toward the carrier.
RCPH10TLB690ABL 8
RCPH10TLB689ABL 9
11. Install the snap rings.
RCPH10TLB688ABL 10
NOTE: Steps 12 through 17 are for the 590SN.

12. Apply petroleum jelly to the inside of the pinion gears.
RCPH10TLB666ABL 11
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13. Install needles in each pinion gear using petroleum

jelly to hold the needles in place.
RCPH10TLB667ABL 12
14. Install the pinion gears onto the pinion shafts.
RCPH10TLB668ABL 13
15. Install needles into the top of the pinion gears.
RCPH10TLB679ABL 14
RCPH10TLB664ABL 15
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RCPH10TLB665ABL 16
18. Press bushings into the hub as required.
RCPH10TLB671ABL 17
19. Install the hub.
RCPH10TLB663ABL 18
20. Install the retaining rings.
RCPH10TLB661ABL 19
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21. Install inner bearing on the swivel housing.
RCPH10TLB658ABL 20
RCPH10TLB659ABL 21
23. Clean seal surface prior to wheel hub installation.
RCPH10TLB678ABL 22
24. Ensure the surface of the seal is clean and dry prior
to installing the wheel hub.
RCPH10TLB681ABL 23
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25. Install the wheel hub onto the swivel housing.
RCPH10TLB656ABL 24
26. Install outer bearing.
RCPH10TLB655ABL 25
27. Align the holes in the hub with the holes in the swivel
housing and install the ring gear.
RCPH10TLB677ABL 26
28. Put Loctite 270 in the female threads in the wheel

hub. Install and tighten the bolts evenly to pull the
hub against the wheel hub. Tighten the bolts to a
final torque of 95 Nm (70 pound-feet).
RCPH10TLB651ABL 27
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29. Ensure shaft is all the way out prior to installing thrust
washers and snap ring.
RCPH10TLB649ABL 28
30. Install the thrust washer with the external tabs.
RCPH10TLB649ABL 29
31. Install the thrust washer with the internal tabs.
RCPH10TLB648ABL 30
RCPH10TLB647ABL 31
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33. Install new O-ring on the carrier.
RCPH10TLB680ABL 32
34. Install the carrier.
RCPH10TLB646ABL 33
35. Install and tighten the Allen head bolts to 80 Nm (59

pound-feet).
RCPH10TLB644ABL 34
36. Fill the 580 SN-WT planetary(ies) with 80W/40 0.59

liters (0.63 U.S. quarts). Fill the 590 SN plane-
tary(ies) with 80W/40 0.65 liters (0.69 U.S. quarts).
47365539 08/07/2012
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37. Install the plug and torque to 80Nm (59 pound-feet).
RCPH10TLB642ABL 35
Next operation:
Axle housing - Disassemble (25.100)
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Index

Planetary drive and hub - Assemble - CNH Front Axle Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Planetary drive and hub - Assemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . 36
Planetary drive and hub - Assemble - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . 51
Planetary drive and hub - Disassemble - CNH Front Axle Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Planetary drive and hub - Disassemble - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . 29
Planetary drive and hub - Disassemble - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . 42
Planetary drive and hub - Exploded view - CNH Front Axle - Planetary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Planetary drive and hub - Exploded view - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . 4
Planetary drive and hub - Exploded view - Carraro Front axle-four wheel drive - 580SN-WT . . . . . . . . . . . . . . . . . . 6
Planetary drive and hub - Exploded view - Carraro Front axle-four wheel drive - 590SN . . . . . . . . . . . . . . . . . . . . . 8
Planetary drive and hub - Inspect - CNH Front Axle Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Planetary drive and hub - Inspect - Carraro Front axle-four wheel drive - 580N and 580SN only . . . . . . . . . . . . . 35
Planetary drive and hub - Inspect - Carraro Front axle-four wheel drive - 580SN-WT and 590SN only . . . . . . . . 50
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Non-powered front axle - 400
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
Front axle
Torque - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
580N, 580SN NA, 580SN WT, 590SN NA
Special tools - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

580N, 580SN NA, 580SN WT, 590SN NA
General specification - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

580N, 580SN NA, 580SN WT NA, 590SN NA
Special tools - CNH Front axle Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

580N, 580SN NA, 580SN WT, 590SN NA
SERVICE
Front axle
Remove - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
580N NA, 580SN NA, 590SN NA
Install - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Disassemble - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Inspect - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Assemble - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Disassemble - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Inspect - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Assemble - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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CONSUMABLES INDEX
Consumable IU PAGE
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Front axle system - Non-powered front axle
Front axle - Torque - Carraro Front axle two wheel drive

580N, 580SN NA, 580SN WT, 590SN NA

Tie rod ball joint to steering cylinder 300 N·m (221.3 lb ft)
Tie rod to steering knuckle 165 N·m (121.7 lb ft)
Jam nut for tie rod 120 N·m (88.5 lb ft)
Bolts for king pin 120 N·m (88.5 lb ft)
Bearing cap plug 15 N·m (11.1 lb ft)
Front axle - Special tools - Carraro Front axle two wheel drive
580N, 580SN NA, 580SN WT, 590SN NA
CAS-1842 Wheel stud removal and installation
RCPH10TLB466ABL 1
CAS-2159 Wrench to loosen and tighten tie rods for steer-

ing cylinder
RCPH10TLB235ABL 2
Front axle - General specification - CNH Front Axle - Two Wheel

Drive
Specifications
Breather 11 - 14 N·m (8.1 - 10.3 lb ft)
Plug, oil drain 54 - 66 N·m (39.8 - 48.7 lb ft)
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Specifications
Drain plug 72 - 88 N·m (53.1 - 64.9 lb ft)
Pinion shaft 1.7 - 2.2 N·m (1.3 - 1.6 lb ft)
Differential 1.5 - 2.5 N·m (1.1 - 1.8 lb ft)
Wheel bearing with seal 12 - 25 N·m (8.9 - 18.4 lb ft)
Open differential 0 - 1 N·m (0.0 - 0.7 lb ft)
Limited slip differential 1 - 5 N·m (0.7 - 3.7 lb ft)
Capacities
Axle
(MAT3510)
NOTE: All hardware is self-locking and uses pre-applied loctite. It is recommended replacing all hardware.
Front axle - Special tools - CNH Front axle Two Wheel Drive
580N, 580SN NA, 580SN WT, 590SN NA
CAS-1842 Wheel stud removal and installation
RCPH10TLB466ABL 1
CAS-2159 Wrench to loosen and tighten tie rods for steer-

ing cylinder
RCPH10TLB235ABL 2
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Front axle - Remove - Two wheel drive machines

Prior operation:
Prior operation:
Front wheels - Remove (44.511)
Prior operation:
Power Shuttle transmission - Remove (21.112) Steps 2, 3, 4 and 5.
1. Raise and support the machine.

2. Install blocks.
RCPH11TLB136AAM 1
3. Identify, tag and disconnect steering hoses. Cap all

open ports.
RCPH11TLB146AAM 2
4. Remove pivot pin lube line.
RCPH11TLB139AAM 3
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5. Support the front axle.
RCPH11TLB140AAM 4
6. Remove rear pivot pin snap ring.
RCPH11TLB141AAM 5
7. Remove bolt and install slide hammer.
RCPH11TLB142AAM 6
8. Remove pivot pin.
RCPH11TLB143AAM 7
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9. Record and remove shims at the front and rear of the

axle pin tube.
RCPH11TLB144AAM 8
10. Carefully lower and remove the front axle.
RCPH11TLB145AAM 9
Next operation:
Powered front axle - Install (25.100)
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Front axle - Install - Two wheel drive machines

Prior operation:
1. Raise the axle into alignment with the machine.
RCPH11TLB140AAM 1
2. Install a spacer (5) between the front of the axle and

the frame.
RCPH11TLB144AAM 2
3. Start the pivot pin (4) into the frame, spacer(s) (5)
and axle.
4. Drive the pivot pin (4) into the rear pivot of the axle
but not through the rear pivot.
5. Install the washer (2) between the rear of the axle
and the frame.
NOTE: Remove or install washer(s) (2) as required be-
tween the axle and the frame to remove any and play.
6. Drive the pivot pin (4) through the rear pivot and the
frame.
7. Install the bolt and snap rings.
RCPH11TLB142AAM 3
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8. Connect the lubrication hose (1) to the fitting.
RCPH11TLB139AAM 4
9. Loosen and remove the plugs from the hoses and the
caps from the fittings for the steering cylinder.
RCPH11TLB146AAM 5
11. Install the wheels and wheel bolts. do not use an

impact wrench to tighten the wheel bolts. Refer to
Front wheels - Install (44.511)
12. Remove the stands and lower the wheels to the floor.
13. Lubricate the pivot pin (4) for the axle.
14. Check and adjust the toe-in according to Four-
Wheel drive (4WD) axle - Drawing (25.100) .
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RCPH10TLB129GAL 6
(1) Remote grease hose (4) Pivot pin

(2) Washer thrust (5) Spacer
(3) Snap ring
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Front axle - Disassemble - Carraro Front axle two wheel drive

1. Loosen and remove the tie rod ends from the swivel
housings.
RCPH10TLB603ABL 1
2. Remove the steering cylinder, ball joints, and tie rod

ends from the axle.
RCPH10TLB716ABL 2
3. Attach suitable lifting equipment to the wheel hub.

Remove the wheel hub cover, bearing retainer plate
bolts, and bearing retainer plate.
RCPH10TLB604ABL 3
4. Remove the wheel hub from the axle.
RCPH10TLB605ABL 4
NOTE: Repeat steps 3 and 4 for the other wheel hub.
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5. Remove the bearing cups from the wheel hubs.
RCPH10TLB606ABL 5
6. Remove the bearing cone from the swivel housing.
RCPH10TLB607ABL 6
7. Attach suitable lifting equipment to the swivel hous-

ing. Remove the upper and lower king pins.
RCPH10TLB608ABL 7
8. Remove the swivel housing from the axle beam.
RCPH10TLB609ABL 8
NOTE: Repeat steps 7 and 8 for the other swivel housing.
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9. Remove the bevelled washers from the axle beam.
RCPH10TLB610ABL 9
10. If required, remove the upper bushing and lower

bearing cup for the king pins.
RCPH10TLB611ABL 10
11. If required, remove the front and rear pivot seals and
bushings.
RCPH10TLB612ABL 11
Next operation:
Powered front axle - Inspect (25.100)
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Front axle - Inspect - Carraro Front axle two wheel drive

Prior operation:
Powered front axle - Disassemble (25.100)

2. Inspect the bearing cups and the rollers in the wheel
damage. Also check the bearing cones for damage.
If any of these defects are found, new wheel bearing
cups and cones must be installed.
3. Inspect king pin bushings and bearings for flat ar-
eas, pitting, scoring, and other damage. Replace as
needed.
4. Inspect axle pivot bushings and pivot pin for flat ar-
needed.
5. Remove and discard all seals and O-rings.
Next operation:
Powered front axle - Assemble (25.100)
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Front axle - Assemble - Carraro Front axle two wheel drive

Prior operation:
1. Install bushings and seals in the pivot on the axle

beam.
RCPH10TLB612ABL 1
NOTE: To ease installation, cool bushings to -100 °C (-148.0 °F).

2. Install the upper bushing and lower bearing cup using
suitable bearing drivers.
RCPH10TLB611ABL 2

3. Apply grease to the bevelled washers to assist hold-
ing them in place during assembly.
RCPH10TLB610ABL 3
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4. Use suitable lifting equipment and install the swivel

housing on the axle.
RCPH10TLB609ABL 4
5. Make sure the bevelled washers are in place, install

the upper and lower king pins. Torque the bolts to
120 N·m (88.5 lb ft)
RCPH10TLB608ABL 5
6. Grease the bearing cone and install it onto the swivel

housing.
RCPH10TLB607ABL 6
7. Use suitable drivers and install new bearing cups and

seal into wheel hub.
RCPH10TLB613ABL 7
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8. Use suitable lifting equipment and install wheel hub

onto the swivel housing.
RCPH10TLB614ABL 8
9. Grease and install the outer bearing on the swivel

housing. Use LOCTITE® 270 on the bolts, position
the thrust washer, install and torque the bolts to 120
N·m (88.5 lb ft).
RCPH10TLB615ABL 9
10. Install a new O-ring on the wheel hub cover, lubricate

the O-ring with grease. Use a suitable driver and
install the wheel hub cover into the wheel hub.
RCPH10TLB616ABL 10
11. Use LOCTITE® 270 on the bolts, mount the steering

cylinder and torque the bolts to 335 N·m (247.1 lb ft).
RCPH10TLB717ABL 11
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12. Install the ball joints to the steering cylinder, torque

the ball joints to 300 N·m (221.3 lb ft).
RCPH10TLB717ABL 12
13. Loosen the locking nut for the tie rod end, place the
swivel housing parallel with the axle. Adjust the tie
rod end so that it can be slipped into the swivel hous-
ing.
RCPH10TLB617ABL 13
14. Tighten the tie rod end to a torque of 165 N·m (121.7
lb ft).
RCPH10TLB603ABL 14
Toe-in Adjustment
15. Place two 1 m (39.37 in) bars on the wheel hubs with
500 mm (19.69 in) on each side of the center line of
the axle.
RCPH10TLB618ABL 15
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16. Use lug nuts to hold the bars into place on the wheel
hub.
RCPH10TLB619ABL 16
17. Measure the distance between the bars, adjust the

toe-in so that (A) is -12 - -24 mm (-0.47 - -0.94 in).
RCPH10TLB718ABL 17
18. Snug the jam nuts for the tie rods and recheck toe-in.
RCPH10TLB620ABL 18
19. Torque the jam nut to 120 N·m (88.5 lb ft).
RCPH10TLB621ABL 19
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Front axle - Disassemble - CNH Front Axle - Two Wheel Drive


2. Remove the nuts and hardened washers and re-
move the wheel(s). Powered front axle - Remove
(25.100) Drain the oil from the carrier.
RCPH10TLB303ACL 1
3. Loosen and remove the tie rod ends from the swivel
housings.
RCPH10TLB951ABL 2
4. Remove the steering cylinder, ball joints, and tie rod

ends from the axle.
RCPH10TLB240ACL 3
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5. Attach suitable lifting equipment to the wheel hub.

Remove the wheel hub cover, bearing retainer plate
bolts, and bearing retainer plate.
RCPH10TLB311ACL 4
6. Remove the wheel hub from the axle.
RCPH10TLB605ABL 5
NOTE: Repeat steps 3 through 6 for the other wheel hub.

7. Remove the bearing cups from the wheel hubs.
RCPH10TLB606ABL 6
8. Remove the bearing cone from the swivel housing.
RCPH10TLB607ABL 7
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9. Attach suitable lifting equipment to the swivel hous-

ing. Remove the upper and lower king pins.
RCPH10TLB954ABL 8
10. Remove the swivel housing from the axle beam.
RCPH10TLB956ABL 9
NOTE: Repeat steps 9 and 10 for the other swivel housing.

11. Remove the bevelled washers from the axle beam.
RCPH10TLB699ABL 10
12. If required, remove the upper bushing and lower

bearing cup for the king pins.
RCPH10TLB926ABL 11
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13. If required, remove the front and rear pivot seals and
bushings.
RCPH10TLB612ABL 12
Next operation:
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Front axle - Inspect - CNH Front Axle - Two Wheel Drive


damage. Also check the bearing cones for damage.
If any of these defects are found, new wheel bearing
cups and cones must be installed.
3. Inspect king pin bushings and bearings for flat ar-
needed.
4. Inspect axle pivot bushings and pivot pin for flat ar-
needed.
5. Remove and discard all seals and O-rings.
Next operation:
Powered front axle - Assemble (25.100)
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Front axle - Assemble - CNH Front Axle - Two Wheel Drive

1. Install bushings and seals in the pivot on the axle

beam.
RCPH10TLB612ABL 1

2. Install the upper bushing and lower bearing cup using
suitable bearing drivers.
RCPH10TLB926ABL 2

3. Apply grease to the bevelled washers to assist hold-
ing them in place during assembly.
RCPH10TLB699ABL 3
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4. Use suitable lifting equipment and install the swivel

housing on the axle.
RCPH10TLB269ACL 4
5. Make sure the bevelled washers are in place, install

the upper and lower king pins. Torque the bolts to
120 N·m (88.5 lb ft)
RCPH10TLB002ACL 5
6. Grease the bearing cone and install it onto the swivel

housing.
RCPH10TLB607ABL 6
7. Use suitable drivers and install new bearing cups and

seal into wheel hub.
RCPH10TLB613ABL 7
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8. Use suitable lifting equipment and install wheel hub

onto the swivel housing.
RCPH10TLB614ABL 8
9. Grease and install the outer bearing on the swivel

housing. Use LOCTITE® 270 on the bolts, position
the thrust washer, install and torque the bolts to 120
N·m (88.5 lb ft).
RCPH10TLB311ACL 9
10. Install a new O-ring on the wheel hub cover, lubricate

the O-ring with grease. Use a suitable driver and
install the wheel hub cover into the wheel hub.
RCPH10TLB616ABL 10
11. Use LOCTITE® 270 on the bolts, mount the steering

cylinder and torque the bolts to 335 N·m (247.1 lb ft).
RCPH10TLB240ACL 11
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12. Install the ball joints to the steering cylinder, torque

the ball joints to 300 N·m (221.3 lb ft).
RCPH10TLB239ACL 12
13. Tighten the tie rod end to a torque of 165 N·m (121.7
lb ft).
RCPH10TLB006ACL 13
Toe-in Adjustment
14. Place two 1 m (39.37 in) bars on the wheel hubs with
500 mm (19.69 in) on each side of the center line of
the axle.
RCPH10TLB618ABL 14
15. Use lug nuts to hold the bars into place on the wheel
hub.
RCPH10TLB619ABL 15
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16. Measure the distance between the bars, adjust the

toe-in so that (A) is -12 - -24 mm (-0.47 - -0.94 in).
RCPH10TLB718ABL 16
17. Snug the jam nuts for the tie rods and recheck toe-in.
RCPH10TLB620ABL 17
18. Torque the jam nut to 120 N·m (88.5 lb ft).
RCPH10TLB621ABL 18
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Index

Front axle - Assemble - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Front axle - Assemble - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Front axle - Disassemble - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Front axle - Disassemble - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Front axle - General specification - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front axle - Inspect - CNH Front Axle - Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Front axle - Inspect - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Front axle - Install - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front axle - Remove - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front axle - Special tools - CNH Front axle Two Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
580N, 580SN NA, 580SN WT, 590SN NA
Front axle - Special tools - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
580N, 580SN NA, 580SN WT, 590SN NA
Front axle - Torque - Carraro Front axle two wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
580N, 580SN NA, 580SN WT, 590SN NA
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PRINTED IN U.S.A.
47365539 08/07/2012
EN
SERVICE MANUAL
Rear axle system
580N
580SN WT
580SN
590SN
47365539 08/07/2012
27
Contents
Rear axle system - 27
Powered rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.100

580N , 580SN WT , 580SN , 590SN
Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.106

580N , 580SN WT , 580SN , 590SN
Planetary and final drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.120

580N , 580SN WT , 580SN , 590SN
47365539 08/07/2012
27
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 270 Wheel hub - Assemble - Wheel hub and brakes - 580N and 27.120 / 31
580SN only
47365539 08/07/2012
27
47365539 08/07/2012
27
Powered rear axle - 100
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
Powered rear axle

General specification - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General specification - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special tools - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FUNCTIONAL DATA
Rear axle housing

Drawing - Axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE
Powered rear axle

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Rear axle system - Powered rear axle
Powered rear axle - General specification - 580N and 580SN only

Gear lubricant Wet brake/Transmission lubricant - SAE 80W140 MAT
3510
Capacity 13.6 l (14.4 US qt)
Special torques
Allen head bolts for hub housing 226 N·m (166.7 lb ft)
Bolts for ring gear 155 N·m (114.3 lb ft)
Bolts for differential support long bolts 80 N·m (59.0 lb ft)
Bolts for differential support short bolts 169 N·m (124.6 lb ft)
Drain hole plugs at wheel hub 60 N·m (44.3 lb ft)
Fill and drain hole plugs at differential 80 N·m (59.0 lb ft)
Ring nut for wheel hub 1000 N·m (737.6 lb ft)
Differential adjusting ring lock screws 10 N·m (88.5 lb in)
Brake self adjuster shouldered bolt 16 N·m (141.6 lb in)
Brake bleeder 8 - 12 N·m (70.8 - 106.2 lb in)
Differential pin plug 25 N·m (18.4 lb ft)
Differential lock plug 180 N·m (132.8 lb ft)
Wheel studs 70 N·m (51.6 lb ft)
Pinion rotating torque (without seal) 2 - 2.4 N·m (17.7 - 21.2 lb in)
Differential bearing preload rotating torque (with seal) 2.6 - 3.3 N·m (23.0 - 29.2 lb in)
Powered rear axle - Special tools - 580N and 580SN only

Differential ring nut wrench 380002433
RCPH10TLB379AAL 1
Pinion depth gauge

1. CAS1596A-4
2. CAS1596A-7
3. CAS1596A-6
4. 380002436
RCPH10TLB380AAL 2
CAS2151A offset spanner wrench used to remove and

install the pinion nut
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OEM4185 universal bearing cup installer - used to install

the hub bearing cups
RCPH10TLB484AAL 3
CAS1716-3 handle (part of CAS1716 Ag tool kit) - Used

with CAS2374 hub seal installer
Yoke to hold shaft. Order p/n 144279A1

Self adjusting brake tools 380002435
RCPH10TLB378AAL 5
Socket for ring nut on wheel flange 380002434
RCPH10TLB377AAL 6
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Seal protector CAS2369

Pinion depth gauge bar 380000407
RCPH10TLB381AAL 7
Wheel hub seal driver 380002431

Spanner wrench CAS1840C
CAS1968 Stud remover/installer - used to remove shoul-
der studs from wheel hubs
RCPH10TLB590AAL 8
Fabricate from locking differential cylinder, used to com-

press differential lock spring to remove "C" clip
RCPH10TLB584AAL 9
Powered rear axle - General specification - 580SN-WT and 590SN

only
Gear lubricant Wet brake/transmission lubricant - SAE 80W140 MAT
3510
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Special torques
Bolts for ring gear 155 N·m (114.3 lb ft)
Bolts for differential support long bolts 80 N·m (59.0 lb ft)
Bolts for differential support short bolts 169 N·m (124.6 lb ft)
Ring nut for wheel hub 1000 N·m (737.6 lb ft)
Differential adjusting ring lock screws 10 N·m (88.5 lb in)
Differential pin plug 25 N·m (18.4 lb ft)
Differential lock plug 180 N·m (132.8 lb ft)
Pinion rotating torque (without seal) 2 - 2.4 N·m (17.7 - 21.2 lb in)
Differential bearing preload rotating torque (without seal) 2.6 - 3.3 N·m (23.0 - 29.2 lb in)
Powered rear axle - Special tools - 580SN-WT and 590SN only

Differential ring nut wrench - 380002433
RCPH10TLB379AAL 1
False pinion - 380100090
RCPH10TLB380AAL 2
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Offset spanner wrench - used to remove and install the

pinion nut - 380100093
RCPH10TLB637ABL 3
Universal bearing cup installer - used to install the hub

bearing cups - OEM4185
RCPH10TLB484AAL 4
Handle (part of CAS1716 Ag tool kit) - Used with CAS2374

hub seal installer - CAS1716-3
RCPH10TLB485AAL 5
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Yoke to hold shaft - 144279A1
RCPH10TLB638ABL 6
Self adjusting brake tools - 380002435
RCPH10TLB378AAL 7
Socket for ring nut on wheel flange - 380002434
RCPH10TLB377AAL 8
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Seal protector - CAS2369
RCPH10TLB635ABL 9
Pinion depth gauge bar - 380000407
RCPH10TLB381AAL 10
Wheel hub seal driver - 380002431
RCPH10TLB636ABL 11
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Seal driver - 380002432
RCPH10TLB634ABL 12
Spanner wrench - CAS1840C
RCPH10TLB633ABL 13
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Rear axle housing - Drawing - Axle housing

Axle housing
(1) Vent
(2) Axle housing
(3) Plugs
(4) Pin D15x35
(5) Bolt M6x25
(6) Differential support
(7) Bolt M12x100
(8) Bolt M12x1.75
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RCPH10TLB7GAL 1
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Powered rear axle - Remove

1. Raise and support the machine.
2. Drain oil from the differential. Use a container capa-

ble of holding 20 l (22 US qt).
RCPH11TLB122AAM 3
3. Drain oil from brake hubs.
RCPH11TLB123AAM 4
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4. Reinstall drain plugs.
RCPH11TLB124AAM 5
RCPH11TLB123AAM 6
5. Remove rear shaft drive hardware.
RCPH11TLB125AAM 7
6. Remove the shaft from the yoke.
RCPH11TLB076AAL 8
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7. Remove rear drive shaft.
RCPH11TLB125AAM 9
8. Disconnect differential lock hose. Cap all open ports.
RCPH11TLB124AAM 10
9. Remove left hand and right hand brake hose guard

hardware.
RCPH11TLB126AAM 11
10. Disconnect brake hoses and cap all open ports.

11. Remove guards.
RCPH11TLB127AAM 12
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12. Position jack underneath axle.
RCPH11TLB128AAM 13
13. Remove hardware securing the axle to the frame.
RCPH11TLB129AAM 14
14. Carefully lower and remove axle.
RCPH11TLB130AAM 15
Next operation:
Powered rear axle - Install (27.100)
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Powered rear axle - Install

1. Position the rear axle under the machine, slowly raise
the axle and align with the mounting holes in the
chassis wheel wells.
RCPH11TLB130AAM 1
2. Install the bolts. Tighten the bolts evenly to pull the

axle against the frame, torque bolts to 610 - 680 N·m
(450 - 500 lb ft) .
RCPH11TLB129AAM 2
3. Remove the jack from underneath axle.
RCPH11TLB128AAM 3
4. Slide the guards over the brake hoses. Remove the

caps from the hoses and connectors. Reconnect the
brake hoses.
RCPH11TLB127AAM 4
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5. Install the left hand and right hand brake hose guard
hardware.
RCPH11TLB126AAM 5
6. Reconnect the differential lock hose.
RCPH11TLB124AAM 6
7. Install the rear drive shaft.

8. Install the shaft into the yoke.
9. Install the rear shaft drive hardware.
RCPH11TLB125AAM 7
10. Refill the brake hubs with oil.

11. Refill the differential with oil.
RCPH11TLB123AAM 8
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12. Reinstall the rear wheels. Raise the machine and

remove the supports.
RCPH11TLB120AAM 9
RCPH11TLB121AAM 10
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Index

Powered rear axle - General specification - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered rear axle - General specification - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Powered rear axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Powered rear axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Powered rear axle - Special tools - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Powered rear axle - Special tools - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Rear axle housing - Drawing - Axle housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Rear bevel gear set and differential - 106
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Differential
Exploded view - Differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view - Differential - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view - Ring and pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exploded view - Differential - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE
Differential
Remove - Carrier removal 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassemble - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove - Differential lock fork removal - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install - Differential lock housing and piston - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Install - Differential lock fork installation - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assemble - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Adjust - Pinion gear backlash adjustment - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Adjust - Differential bearing preload adjustment - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Install - Pinion shaft seal installation - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Install - Carrier installation - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Check - Checking the differential lock - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Remove - Carrier removal - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disassemble - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Remove - Differential lock for removal - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Install - Differential lock for installation - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Assemble - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Adjust - Pinion gear backlash adjustment - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Adjust - Differential bearing preload adjustment - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . 83
Install - Pinion shaft seal installation - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Install - Carrier Installation - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Check - Checking the differential lock - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
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Rear axle system - Rear bevel gear set and differential
Differential - Exploded view - Differential lock

Differential lock
1. Cylinder 6. Bushing
2. Cylinder O-ring 7. Spring
3. Piston 8. Shaft
4. Piston O-rings 9. Fork
5. Locking ring
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RCPH10TLB9GAL 1
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27.106 / 5
Differential - Exploded view - Differential - 580N and 580SN only

Differential
1. Ring nut 11. Spider gear
2. Bearing 12. Differential pin
3. Sleeve 13. Pin
4. Cap screw M12 x 25 14. Spacer
5. Pin 15. Housing cover
6. O-ring 16. Locking ring
7. Housing 17. Locking side spider gear
8. Thrust washer 18. Differential pin
9. Plug 19. Side spider gear
10. Thrust washer 20. Pin
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RCPH10TLB10GAL 1
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27.106 / 7
Differential - Exploded view - Ring and pinion

Ring and pinion
1. Ring gear 7. Outer bearing
2. Pinion gear 8. Lock washer
3. Shim 9. Ring nut
4. Inner bearing 10. Seal
5. Washer 11. O-ring
6. Crush sleeve 12. Cap
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RCPH10TLB11GAL 1
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27.106 / 9
Differential - Exploded view - Differential - 580SN-WT and 590SN

only
(1) Ring nut
(2) Bearing
(3) Sleeve
(4) Cap screw M12 x 25
(5) Pin
(6) O-ring
(7) Housing
(8) Thrust washer
(9) Plug
(10) Thrust washer
(11) Spider gear
(12) Differential pin
(13) Pin
(14) Spacer
(15) Housing cover
(16) Locking ring
(17) Locking side spider gear
(18) Differential pin
(19) Side spider gear
(20) Pin
(21) Thrust washer
(22) Plug
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RCPH10TLB13GAL 1
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27.106 / 11
Differential - Remove - Carrier removal 580N and 580SN only

1. Remove the wheel hubs and brakes, see Wheel
Hubs And Brakes Disassembly in this section.
2. Remove the differential mounting bolts.
RCPH10TLB373AAL 1
3. Use pry bars in slots.
RCPH10TLB374AAL 2
4. Have an assistant hold the differential housing up

away from the axle housing, attach a lifting eye to
the bottom of the differential housing.
RCPH10TLB370AAL 3
47365539 08/07/2012
27.106 / 12

away from the axle housing, attach a lifting eye to
the top of the differential housing.
RCPH10TLB371AAL 4
6. Attach lifting equipment to lifting eyes.
RCPH10TLB369AAL 5
7. Remove the differential and place on a work bench.
Next operation:
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Differential - Disassemble - 580N and 580SN only

1. Remove the bolts securing the ring nut.
RCPH10TLB364AAL 1
2. Remove the ring nuts.
RCPH10TLB362AAL 2
3. Remove the differential from the carrier.

4. The bearing cups can be removed with a roll head
pry bar if replacement is needed.
RCPH10TLB432AAL 3
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27.106 / 14
5. Remove the locking ring.
RCPH10TLB433AAL 4
6. Remove the differential housing cover, remove the

anti rotation pin.
RCPH10TLB434AAL 5
7. The thrust washer may stay on the cover, remove the

thrust washer.
RCPH10TLB435AAL 6
8. Remove the gear from the housing.
RCPH10TLB436AAL 7
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9. Remove three plugs from the differential.
RCPH10TLB437AAL 8
10. Remove the three pins securing the spider pins in the
differential.
RCPH10TLB438AAL 9
11. Remove the ring gear cap screws, remove the ring
gear.
RCPH10TLB440AAL 10
NOTE: Large amounts of Loctite was used during assembly, remove cap screws slowly. If screw binds, turn back in
and then back out.
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12. Note the flat surface on pin (1) and spacer (2).
RCPH10TLB441AAL 11
13. Push the pin towards the flat surface side noted in
the previous step.
RCPH10TLB442AAL 12
NOTE: DO NOT force the pin, it will not come out of the housing at this time.
14. Remove the spider gear and thrust washer.
RCPH10TLB443AAL 13
15. Push the pin out of the housing.
RCPH10TLB444AAL 14
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RCPH10TLB445AAL 15
17. Push one of the short spider pins out of the spacer
by pushing it through the hole in the spacer.
RCPH10TLB446AAL 16
NOTE: Do not remove the pin at this time, leave the pin in far enough to support the spider gear and thrust washer.
18. Push the other short spider pin out of the spacer by
pushing it through the hole in the spacer.
RCPH10TLB447AAL 17
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27.106 / 18
19. Remove the spacer from the housing.
RCPH10TLB448AAL 18
20. Remove the spider pin, gear and thrust washer from
the housing.
RCPH10TLB449AAL 19
21. Remove the other pin, gear and thrust washer from
the housing.
RCPH10TLB450AAL 20
22. Remove the gear and thrust washer from the hous-
ing.
RCPH10TLB452AAL 21
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23. Remove the differential locking pins from the hous-

ing.
RCPH10TLB359AAL 22
24. Remove the cover and seal from the carrier.
RCPH10TLB340AAL 23
25. The pinion gear nut is staked into place on the pinion
shaft.
RCPH10TLB341AAL 24
26. Use a chisel punch to remove the stake from the

pinion shaft NUT.
RCPH10TLB342AAL 25
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27. Use the offset spanner, CAS2151A, and yoke P/N

144279A1 to remove the pinion gear ring nut.
RCPH10TLB343AAL 26
28. Use a soft faced hammer and drive the pinion out of
the carrier housing.
29. Remove the crush sleeve and shims from the pinion
shaft.
RCPH10TLB344AAL 27
30. Press the bearing from the pinion shaft.
RCPH10TLB345AAL 28
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31. Remove the shim from the pinion.
RCPH10TLB346AAL 29
32. Remove the outer bearing cup from the carrier.
RCPH10TLB347AAL 30
33. Remove the inner bearing cup from the carrier.
RCPH10TLB348AAL 31
Next operation:
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Differential - Remove - Differential lock fork removal - 580N and

580SN only
NOTE: The differential lock fork may look different for machines equipped with a Power Shift transmission. The
procedure is the same.
1. Loosen the differential lock cylinder from the carrier.
RCPH10TLB349AAL 1
2. Hold the differential lock fork down to catch a block

inside of the housing, remove the cylinder.
RCPH10TLB350AAL 2
NOTE: Use caution removing the cylinder, it is under spring pressure.

3. Place a flat washer over the shaft.
RCPH10TLB351AAL 3
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4. Start the modified cylinder into the differential hous-

ing.
RCPH10TLB352AAL 4
5. Block the fork from moving.
RCPH10TLB353AAL 5
6. Tighten the modified cylinder and press down on the

bushing, remove the snap ring.
RCPH10TLB354AAL 6
RCPH10TLB355AAL 7
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RCPH10TLB356AAL 8
9. Remove the shaft.
RCPH10TLB357AAL 9
10. Remove the fork, spring and bushing from the shaft.
RCPH10TLB460AAL 10
Next operation:
Differential - Install (27.106)
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Differential - Install - Differential lock housing and piston - 580N

and 580SN only
1. Install new O-rings on the piston. Lubricate the
O-rings with clean hydraulic oil. Install a new O-ring
on the cover for the differential lock.
RCPH10TLB459AAL 1
2. Lubricate the bore in the cover for the piston with

clean hydraulic oil. Install the piston in the cover for
the differential lock.
Next operation:
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Differential - Install - Differential lock fork installation - 580N and

580SN only
NOTE: The differential lock fork will look different for machines equipped with a Power Shift transmission. The pro-
cedure is the same.
1. When installing the bushings on the shaft make sure
the chamfer is over the snap ring.
RCPH10TLB461AAL 1
2. Lubricate the shaft with clean hydraulic oil. Install the

fork on the shaft with collar towards snap ring (1).
Install bushing (2) and spring (3) onto shaft.
RCPH10TLB460AAL 2
3. Install the shaft into the carrier.
RCPH10TLB357AAL 3
47365539 08/07/2012
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RCPH10TLB356AAL 4
5. Place the bushing on the shaft, make sure the cham-

fer in the bushing is facing out.
RCPH10TLB355AAL 5
6. Place a flat washer over the shaft.
RCPH10TLB351AAL 6
7. Start the modified cylinder into the differential hous-

ing.
RCPH10TLB352AAL 7
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8. Block the fork from moving.
RCPH10TLB353AAL 8
9. Compress the spring by tightening the modified cylin-

der and install the snap ring.
RCPH10TLB354AAL 9
10. Remove the block, push the fork into the carrier and
lock it behind the block inside of the carrier. Hand
start the locking cylinder.
RCPH10TLB350AAL 10
11. Torque the locking cylinder to 180 Nm (133 pound-

feet).
RCPH10TLB360AAL 11
Next operation:
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Differential - Assemble - 580N and 580SN only

1. Install new O-rings on the pins. Lubricate the O-rings
with clean hydraulic oil.
RCPH10TLB481AAL 1
2. Install the pins in the differential housing.
RCPH10TLB358AAL 2
3. Lubricate the gear and thrust washer with clean hy-

draulic oil. Install the gear and thrust washer.
RCPH10TLB452AAL 3
4. When installing the pins and thrust washers, align the

flats on the pins with the flats in the thrust washer.
RCPH10TLB451AAL 4
47365539 08/07/2012
27.106 / 31
5. Install the pin, thrust washer and spider gear.
RCPH10TLB450AAL 5
NOTE: Push the pin in just far enough to hold the thrust washer and spider.
6. Install the pin, thrust washer, and spider gear.
RCPH10TLB449AAL 6
7. Install the spacer as shown, push the pins into the
spacer.
RCPH10TLB448AAL 7
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27.106 / 32
8. Make sure to install the pin so that the dowel pin hole
aligns with the dowel pin hole in the housing.
RCPH10TLB445AAL 8
9. Place the spider gear and thrust washer into the

housing. Align the bushing with the pin and push the
pin in as far as possible.
RCPH10TLB444AAL 9
10. Install the spider gear and thrust washer, push the
pin into the gear and washer.
RCPH10TLB443AAL 10
11. Install the retaining pins for the spider gear pins into
the housing.
47365539 08/07/2012
27.106 / 33
12. The pinion gear and ring gear are a matched set.
Make sure the numbers on the pinion gear and ring
gear are the same.
RCPH10TLB589AAL 11
13. Use LOCTITE 270 on cap screws, install and torque

ring gear cap screws to 155 Nm (114 pound-feet).
RCPH10TLB439AAL 12
NOTE: Torque cap screws in a staggered pattern in order to draw the ring gear up flush.
14. Install plugs and torque to 25 Nm (18.5 pound-feet).
RCPH10TLB437AAL 13
15. Use an acceptable driver and install a bearing cup

into the housing.
RCPH10TLB457AAL 14
47365539 08/07/2012
27.106 / 34
NOTE: The bearing cup will stay raised above the housing even when properly seated.
16. Place the gear into the housing while aligning the
teeth.
RCPH10TLB436AAL 15
17. Apply a light coat of grease to the thrust washer to

hold it in place on the differential housing cover. The
ears of the thrust washer must align with the slots in
the cover.
RCPH10TLB435AAL 16
18. When installing the differential housing cover, place

the pin in the slot of the cover and align it into the
grove in the housing during assembly.
RCPH10TLB453AAL 17
19. Install the cover into the housing, install the locking
ring.
RCPH10TLB434AAL 18
47365539 08/07/2012
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20. Use an acceptable driver and install the bearing cup.
RCPH10TLB491AAL 19
21. Install the differential lock ring onto the housing. If it

is difficult to push down, reach through the housing
and rotate the spider gears until the differential lock
ring will go down.
RCPH10TLB458AAL 20
22. Use an acceptable driver and install the inner bearing

cup.
RCPH10TLB454AAL 21
23. Use an acceptable driver and install the outer bearing

cup.
RCPH10TLB455AAL 22
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27.106 / 36
24. Install the inner bearing.
RCPH10TLB390AAL 23
25. Install depth gauge 380002436, adapter

CAS1596A-6, and bolt CAS1596A-7 into the
bearing.
RCPH10TLB389AAL 24
26. CAS1596A-4 must be facing up as shown.
RCPH10TLB391AAL 25
27. Place the outer bearing on CAS1596-A as shown.
RCPH10TLB392AAL 26
47365539 08/07/2012
27.106 / 37
28. Tighten CAS1596A-4 and 380002436 until the bear-

ings are tight.
RCPH10TLB388AAL 27
29. Place CAS1716-3 handle in bearing cradles of the

carrier housing.
RCPH10TLB387AAL 28
NOTE: Make sure the carrier housing is level.

between the gauge block and the gauge tube. Write
the measurement on line “b” in step 32.
RCPH10TLB386AAL 29
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31. Find the number on the end of the pinion shaft. Write
this number on line “d” of the worksheet.
RCPH10TLB480AAL 30
32. See the example and worksheet. The number on line

“a” does not change. Add line “a” and line “b” and
write the answer on line “c”. Subtract line “d” from
line “c” and write the answer on line “e”. Line “e” is
the thickness of the shim to be installed on the pinion
shaft.
Example
a. 74.6 mm a. Tool constant
b. +0.203 mm b. Gap measurement
c. 74.803 mm c. Total distance
d. - 68 mm d. Reading on pinion
e. 6.803 mm e. Required shim thickness
Worksheet
a. 74.6 mm a. Tool constant
b. + mm b. Gap measurement
c. mm c. Total distance
d. - mm d. Reading on pinion
e. mm e. Required shim thickness
33. Remove the special tools from the center section.

34. Install the shim with the thickness specified in step
32. The chamfer on the ID of the shim must be to-
ward the pinion gear.
RCPH10TLB482AAL 31
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27.106 / 39
35. Put the inner bearing in position on the shaft.
RCPH10TLB483AAL 32
36. Use a suitable driver and press the inner bearing

against the shim.
RCPH10TLB483AAL 33
37. Lubricate the bearing with hydraulic oil. Install the

washers and a new collapsible spacer on the pinion
gear. The old collapsible spacer MUST NOT be used
again.
RCPH10TLB462AAL 34
38. Lubricate the outer bearing with hydraulic oil. Install

the outer bearing.
RCPH10TLB463AAL 35
47365539 08/07/2012
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39. Install the special washer, make sure to align the

washer with the slot in the pinion shaft.
RCPH10TLB464AAL 36
40. Lubricate the face of the nut, special washer and

threads with hydraulic oil. Install the pinion nut.
RCPH10TLB465AAL 37
41. Use the P/N 144279A1 Yoke and the CAS2151A to

start the pinion nut onto the pinion gear.
RCPH10TLB466AAL 38
42. Install the CAS2375 on the pinion shaft.
NOTICE: If the pinion nut is tightened too much (rotating torque more than specified), pinion shaft must be removed
and a new collapsible spacer must be installed.
47365539 08/07/2012
27.106 / 41
43. Use the torque wrench to check the rotating torque of

the pinion gear. The rotating torque of the pinion gear
must be 2 to 2.4 Nm (17.7 to 21.1 pound-inches).
RCPH10TLB467AAL 39
44. Remove the torque wrench and the CAS2375 from

the pinion shaft.
45. Use the yoke and the CAS2151A to tighten the pinion
nut in SMALL amounts as required. Repeat steps 40
through 44 until the rotating torque is as specified in
step 43.
RCPH10TLB466AAL 40
46. Stake the lip on the pinion nut into the slot in the
pinion shaft.
RCPH10TLB468AAL 41
47365539 08/07/2012
27.106 / 42
47. Use an acceptable driver and install the bearings

onto the ring nuts.
RCPH10TLB456AAL 42
48. Install the differential housing into the carrier. Tighten

the ring nuts evenly and center the differential hous-
ing in the carrier.
RCPH10TLB362AAL 43
Next operation:
Differential - Adjust (27.106)
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Differential - Adjust - Pinion gear backlash adjustment - 580N and

580SN only
1. Mount a dial indicator onto the carrier, set the shaft
of the dial indicator onto the center of a tooth of the
ring gear.
RCPH10TLB361AAL 1
2. Use your hand and move the ring gear back and
forth to check for backlash. Check back lash at three
points on the ring gear approximately 120° apart.
3. The pinion gear backlash must be 0.20 to 0.29 mm
(0.008 to 0.011 inch). If the backlash is not correct
do the following procedure.
4. If there is not enough backlash, loosen (turn counter-
clockwise) the adjusting ring on the other side of the
center section one notch. tighten (turn clockwise) the
adjusting ring one notch on the side shown. Continue
with this step until the backlash is 0.20 to 0.29 mm
(0.008 to 0.011 inch). If there is too much backlash,
loosen (turn counterclockwise) the adjusting ring on
the side shown one notch. tighten (turn clockwise)
the adjusting ring one notch on the side opposite of
that shown. Continue with this step until the back-
lash is 0.20 to 0.29 mm (0.008 to 0.011 inch).
RCPH10TLB362AAL 2
Next operation:
47365539 08/07/2012
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Differential - Adjust - Differential bearing preload adjustment - 580N

and 580SN only
1. Install the CAS2375 on the pinion shaft. Check
the rotating torque of the pinion shaft. The ro-
tating torque must be 2.6 to 3.3 Nm (23 to 29
pound-inches).
RCPH10TLB469AAL 1
2. If the rotating torque is not correct do the following

procedure.
3. If the rotating torque is too high, loosen (turn counter-
clockwise) the adjusting ring one notch on both sides.
Continue with this step until the rotating torque is 2.6
to 3.3 Nm (23 to 29 pound-inches). If the rotating
torque is too low, tighten (turn clockwise) the adjust-
ing ring one notch on both sides. Continue with this
step until the rotating torque is 2.6 to 3.3 Nm (23 to
29 pound-inches).
RCPH10TLB362AAL 2
4. Secure the adjusting rings with the Allen screws,

torque the Allen screws to 10 Nm (88.5 pound
inches).
RCPH10TLB363AAL 3
Next operation:
47365539 08/07/2012
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Differential - Install - Pinion shaft seal installation - 580N and 580SN

only
1. Use seal driver, 380002432, and drive the seal into
the cover. The lips on the seal must be toward the
inside of the cover.
RCPH10TLB366AAL 1
RCPH10TLB365AAL 2
3. Put the CAS2369 Pinion Spline Seal Protector on the

pinion gear shaft.
RCPH10TLB367AAL 3
47365539 08/07/2012
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stall the cover on the center section.
RCPH10TLB368AAL 4
5. Remove the CAS2369 from the pinion gear shaft.
Next operation:
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Differential - Install - Carrier installation - 580N and 580SN only

1. Apply a coat of Loctite 510 to the mating surface for
the carrier.
RCPH10TLB470AAL 1
2. Attach lifting equipment to the carrier and place onto

the axle housing.
RCPH10TLB369AAL 2
3. Remove the lifting equipment from the carrier, use a

rubber mallet and tap the carrier until the dowel pins
are fully seated.
4. Use Loctite 638 on carrier bolts and torque the short
carrier bolts to 169 Nm (124.5 pound-feet). Torque
the long carrier bolts to 80 Nm (59 pound-feet).
RCPH10TLB372AAL 3
NOTE: DO NOT use any thread locking compound on these bolts.
Next operation:
Differential - Check (27.106)
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Differential - Check - Checking the differential lock - 580N and

580SN only
1. Connect a hand pump and gauge to the fitting on the
differential lock. Have someone turn the wheel hub
as slight pressure is applied to the hand pump. If the
differential lock is working correctly the wheel hub
will become hard to turn and the wheel hub on the
opposite side of the axle will turn at the same time.
NOTE: Make sure the air is removed from the brake system when the axle is installed on the machine.
47365539 08/07/2012
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Differential - Remove - Carrier removal - 580SN-WT and 590SN only

1. Remove the wheel hubs and brakes, see Wheel
Hubs And Brakes Disassembly in this section.
2. Remove the differential mounting bolts.
RCPH10TLB532AAL 1
3. Use pry bars in slots to loosen the carrier from the

axle housing.
RCPH10TLB531AAL 2

away from the axle housing, attach suitable lifting
equipment to the differential housing.
RCPH10TLB530AAL 3
Next operation:
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Differential - Disassemble - 580SN-WT and 590SN only

2. Remove the bolts securing the ring nut.
RCPH10TLB535AAL 1
3. Remove the ring nuts.
RCPH10TLB362AAL 2
4. Remove the differential from the carrier.

5. Remove the differential lock sleeve.
RCPH10TLB552AAL 3
47365539 08/07/2012
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6. Remove the locking ring.
RCPH10TLB545AAL 4
7. Use a plate just large enough to cover the side gear

and will not interfere with the removal of the differen-
tial housing cover.
RCPH10TLB544AAL 5
8. Use an acceptable puller to remove the differential

housing cover.
RCPH10TLB546AAL 6
RCPH10TLB547AAL 7
47365539 08/07/2012
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10. Remove the bearing cup.
RCPH10TLB550AAL 8
RCPH10TLB548AAL 9
12. Remove the anti-rotation pin.
RCPH10TLB549AAL 10
13. Remove three plugs from the differential.
RCPH10TLB551AAL 11
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14. Remove the three pins securing the spider pins in the
differential.
RCPH10TLB553AAL 12
15. Note the flat surface on pin.
RCPH10TLB554AAL 13
16. Push the pin towards the flat surface side noted in
the previous step.
RCPH10TLB512AAL 14
NOTE: DO NOT force the pin, it will not come out of the housing at this time.
RCPH10TLB511AAL 15
47365539 08/07/2012
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18. Push the pin out of the housing.
RCPH10TLB516AAL 16
RCPH10TLB511AAL 17
20. Push one of the short spider pins out of the spacer
by pushing it through the hole in the spacer.
RCPH10TLB585AAL 18
21. Push the other short spider pin out of the spacer by
pushing it through the hole in the spacer.
RCPH10TLB586AAL 19
47365539 08/07/2012
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22. Remove the spacer from the housing.
RCPH10TLB555AAL 20
23. Remove the spider pin, gear and thrust washer from
the housing.
RCPH10TLB556AAL 21
24. Remove the other pin, gear and thrust washer from
the housing.
RCPH10TLB556AAL 22
25. Remove the gear from the housing.
RCPH10TLB504AAL 23
47365539 08/07/2012
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26. Remove the thrust washer from the housing.
RCPH10TLB502AAL 24
27. Remove the ring gear cap screws, remove the ring.
RCPH10TLB492AAL 25
NOTE: Large amounts of Loctite was used during assembly, remove cap screws slowly. If screws bind, turn back in
and then back out.
28. Remove the differential locking pins from the hous-
ing.
RCPH10TLB495AAL 26
47365539 08/07/2012
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29. Remove the cover and seal from the carrier.
RCPH10TLB538AAL 27
30. The pinion gear nut is staked into place on the pinion
shaft.
RCPH10TLB539AAL 28
31. Use a chisel punch to remove the stake from the

pinion shaft nut.
RCPH10TLB540AAL 29
32. Use the offset spanner, 380100093, and yoke P/N

144279A1 to remove the pinion gear ring nut.
RCPH10TLB541AAL 30
47365539 08/07/2012
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33. Use a soft faced hammer and drive the pinion out of
the carrier housing.
RCPH10TLB559AAL 31
34. Remove the crush sleeve and shims from the pinion
shaft.
RCPH10TLB561AAL 32
35. Press the bearing from the pinion shaft.
RCPH10TLB575AAL 33
36. Remove the shim from the pinion.
RCPH10TLB576AAL 34
47365539 08/07/2012
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37. Remove the outer bearing cup from the carrier.
RCPH10TLB580AAL 35
38. Remove the inner bearing cup from the carrier.
RCPH10TLB579AAL 36
Next operation:
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Differential - Remove - Differential lock for removal - 580SN-WT

and 590SN only
1. Remove elbow from the differential lock cylinder.
RCPH10TLB562AAL 1
2. Loosen the differential lock cylinder from the carrier.
RCPH10TLB563AAL 2
NOTE: Use caution removing the cylinder, it is under spring pressure.

3. Loosen the differential cylinder plug.
RCPH10TLB564AAL 3
47365539 08/07/2012
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4. Remove the differential cylinder plug from the carrier.
RCPH10TLB566AAL 4
5. Remove the differential lock fork.
RCPH10TLB567AAL 5
6. Place differential lock fork in a soft-jawed vise.

Tighten vise enough to gain access to the snap ring.
Remove the snap ring.
RCPH10TLB570AAL 6
7. Remove the fork.
RCPH10TLB572AAL 7
47365539 08/07/2012
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RCPH10TLB573AAL 8
RCPH10TLB574AAL 9
Next operation:
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Differential - Install - Differential lock for installation - 580SN-WT

and 590SN only
NOTE: When installing the bushings on the shaft, make sure the chamfer is over the snap ring.
1. When installing the bushings on the shaft make sure
the chamfer is over the snap ring.
RCPH10TLB574AAL 1
2. Install the spring onto the shaft.
RCPH10TLB573AAL 2
3. Install the fork onto the shaft with collar of fork to-
wards the retaining ring.
RCPH10TLB572AAL 3
NOTE: Position fork as shown.
47365539 08/07/2012
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4. Place differential lock fork in a soft-jawed vise.

Tighten vise enough to gain access to the snap ring.
Install the snap ring.
RCPH10TLB571AAL 4
5. Install shaft into the carrier.
RCPH10TLB569AAL 5
6. Install the bushing and spring.
RCPH10TLB568AAL 6
7. Position bushing in the opening in the carrier.
RCPH10TLB567AAL 7
47365539 08/07/2012
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8. Install a new O-ring on the plug for the differential

lock.
RCPH10TLB566AAL 8
9. Tighten the differential lock plug to a torque of Nm

180 (133 Pound-feet).
RCPH10TLB565AAL 9
10. Install and tighten the differential lock cylinder to a

torque of 180 Nm (133 Pound-feet).
RCPH10TLB563AAL 10
11. Install new O-ring on elbow. Install elbow to the

proper position and tighten jam nut to a torque of 30
Nm (262 Pound-inches).
RCPH10TLB562AAL 11
Next operation:
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47365539 08/07/2012
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Differential - Assemble - 580SN-WT and 590SN only

1. Install ring gear.
RCPH10TLB494AAL 1
2. Use two Allen head screws to hold the ring gear in

place.
RCPH10TLB496AAL 2
3. Tighten the screws evenly to pull the ring gear par-

tially into position.
RCPH10TLB497AAL 3
4. Install two ring gear screws in the ring gear.
RCPH10TLB498AAL 4
47365539 08/07/2012
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5. Tighten the screws evenly to draw up the ring gear.
RCPH10TLB499AAL 5
6. Remove the two long Allen head screws.
RCPH10TLB500AAL 6
7. Apply Loctite 270 on the screws. Install ring gear cap

screws.
RCPH10TLB501AAL 7
8. Tighten cap screws to a torque of 155 Nm (114

Pound-feet).
RCPH10TLB493AAL 8
47365539 08/07/2012
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RCPH10TLB503AAL 9
10. Install the side gear with differential lock slots.
RCPH10TLB504AAL 10
11. When installing the pins and thrust washers, align the
flats on the pins with the flats in the thrust washer.
RCPH10TLB506AAL 11
12. Lubricate thrust washer and spider gear. Install the

spider gear.
RCPH10TLB505AAL 12
47365539 08/07/2012
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13. Make sure to install the pin so that the pin hole aligns
with the pin hole in the housing.
RCPH10TLB507AAL 13
14. Push the pin in just far enough to hold the thrust
washer and spider.
RCPH10TLB508AAL 14
15. Install the pin, thrust washer and spider gear on the
opposite side.
RCPH10TLB509AAL 15
16. Place the spacer between the spider gears as
shown.
RCPH10TLB510AAL 16
47365539 08/07/2012
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17. Make sure to install the pin so that the pin hole (1),
aligns with the pin hole in the housing.
RCPH10TLB513AAL 17
NOTE: Notice the position of the shoulder (2), on the pin.

18. Install the spider gear and thrust washer.
RCPH10TLB511AAL 18
19. Align the bushing with the pin and push the pin into
the bushing.
RCPH10TLB514AAL 19
20. Install the spider gear and thrust washer into the
housing.
RCPH10TLB515AAL 20
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21. Push the pin into the gear and washer.
RCPH10TLB516AAL 21
22. Install the pins for the spider gear shaft.
RCPH10TLB517AAL 22
23. Install plugs and tighten to a toque of 25 Nm (221

Pound-inches).
RCPH10TLB518AAL 23
24. Install side gear.
RCPH10TLB519AAL 24
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25. Install thrust washer.
RCPH10TLB588AAL 25
26. Install bearing cup if removed.
RCPH10TLB550AAL 26
27. Install anti-rotation pin.
RCPH10TLB549AAL 27
28. Align the notch in the bearing housing with the anti-
rotation pin. Install the bearing housing.
RCPH10TLB520AAL 28
47365539 08/07/2012
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RCPH10TLB521AAL 29
30. Install new O-rings on the differential lock pins. Lu-

bricate the O-rings with clean oil. Install pins.
RCPH10TLB522AAL 30
NOTE: Position differential lock sleeve with chaffered side down.

31. Install the lock ring.
RCPH10TLB524AAL 31
32. Install outer bearing cup into the carrier.
RCPH10TLB581AAL 32
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33. Install inner bearing cup into the carrier.
RCPH10TLB582AAL 33
34. The pinion gear and ring gear are a matched set.
Make sure the numbers on the pinion gear and ring
gear are the same.
RCPH10TLB480AAL 34
35. Insert bearing (7) and (8) in the housing. Assemble

the false pinion 380100090 (1a) , spacer (2) , and
ring nut (1) , on the differential carrier (9). Tighten
with the ring nut until the bearings are tight.
RCPH10TLB487AAL 35
36. Place special tool 380000407 (2a) in the differential

group supports (3).
RCPH10TLB583AAL 36
47365539 08/07/2012
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37. Use a depth gauge to measure distance “X” (distance

between the axis of the differential bearings and the
point at which the pinion head is supported, or the
base of the bearing).
RCPH10TLB488AAL 37
38. To adjust bevel gear/pinion, measure the distance

“A” with a depth gauge. Calculate the value “X” as fol-
lows: X=(A+C)-B mm Where “B” and “C” are known.
RCPH10TLB489AAL 38
NOTE: Distance B was not known at time of printing, measure the tool as shown above to obtain distance B. Distance
C is obtained by measuring the internal distance from the bottom of the bearing support to the top and divided by two
(50 MM).
39. S=(X-V) mm In order to determine the necessary
thickness value (S) between the pinion and the bear-
ing, subtract the value (V), stamped on the pinion
head (V = requested distance), from the measured
value (X).
RCPH10TLB480AAL 39
47365539 08/07/2012
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40. Select the shim with the thickness value (S) among
the range of available shims. Shim thickness-mm
RCPH10TLB576AAL 40
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
NOTE: The chamfer of the shim goes toward the gear.

41. Remove special tool 38000408 from the differential
group supports (9). Remove the ring nut (1), spacer
(2), and false pinion 30100090 (1a), and the bearings
(7) and (8).
RCPH10TLB487AAL 41
42. Install the bearing on the shaft.
RCPH10TLB577AAL 42
47365539 08/07/2012
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43. Use a suitable driver and press the bearing onto the
shaft.
RCPH10TLB578AAL 43
44. Lubricate the bearing with hydraulic oil. Install the

washers and a NEW crush sleeve on the shaft. The
old collapsible spacer MUST NOT be used again.
RCPH10TLB561AAL 44
45. Install shaft into the carrier.

46. Heat the outer bearing and install on the shaft.
RCPH10TLB560AAL 45
47. Install the special washer, make sure to align the

washer with the slot in the pinion shaft.
RCPH10TLB558AAL 46
47365539 08/07/2012
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48. Lubricate the face of the nut, special washer and

threads with hydraulic oil. Install the pinion nut.
RCPH10TLB557AAL 47
49. Use the P/N 144279A1 Yoke and the 380100093 to

start the pinion nut onto the pinion gear.
RCPH10TLB541AAL 48
RCPH10TLB528AAL 49
NOTICE: If the pinion nut is tightened too much (rotating torque more than specified), pinion shaft must be removed
and a new collapsible spacer must be installed.
51. Use the torque wrench to check the rotating torque of
the pinion gear. The rotating torque of the pinion gear
must be 2 to 2.4 Nm (17.7 to 21.1 pound-inches).
RCPH10TLB587AAL 50
47365539 08/07/2012
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52. Remove the torque wrench and the CAS2375 from

the pinion shaft.
53. Use the yoke and the 380100093 to tighten the pinion
nut in SMALL amounts as required. Repeat steps
49through 53 until the rotating torque is as specified
in step 51.
RCPH10TLB542AAL 51
54. Stake the lip on the pinion nut into the slot in the
pinion shaft.
RCPH10TLB539AAL 52
55. Use an acceptable driver and install the bearings

onto the ring nuts.
56. Install the differential housing into the carrier. Tighten
the ring nuts evenly and center the differential hous-
ing in the carrier.
RCPH10TLB362AAL 53
Next operation:
47365539 08/07/2012
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Differential - Adjust - Pinion gear backlash adjustment - 580SN-WT

and 590SN only
1. Mount a dial indicator onto the carrier, set the shaft
of the dial indicator onto the center of a tooth of the
ring gear.
RCPH10TLB525AAL 1
2. Use your hand and move the ring gear back and
forth to check for backlash. Check back lash at three
points on the ring gear approximately 120° apart.
RCPH10TLB526AAL 2
3. The pinion gear backlash must be 0.20 to 0.29 mm

(0.008 to 0.011 inch). If the backlash is not correct
do the following procedure.
4. If there is too much backlash, loosen (turn counter-
clockwise) the adjusting ring on the other side of the
center section one notch. tighten (turn clockwise) the
adjusting ring one notch on the side shown. Continue
with this step until the backlash is 0.20 to 0.29 mm
(0.008 to 0.011 inch). If there is not enough backlash,
loosen (turn counterclockwise) the adjusting ring on
the side shown one notch. tighten (turn clockwise)
the adjusting ring one notch on the side opposite of
that shown. Continue with this step until the back-
lash is 0.20 to 0.29 mm (0.008 to 0.011 inch).
RCPH10TLB362AAL 3
Next operation:
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Differential - Adjust - Differential bearing preload adjustment -

RCPH10TLB528AAL 1
2. Check the rotating torque of the pinion shaft. The

rotating torque must be 2.6 to 3.3 Nm (23 to 29
pound-inches).
RCPH10TLB587AAL 2
3. If the rotating torque is not correct do the following

procedure.
4. If the rotating torque is too high, loosen (turn counter-
clockwise) the adjusting ring one notch on both sides.
Continue with this step until the rotating torque is 2.6
to 3.3 Nm (23 to 29 pound-inches). If the rotating
torque is too low, tighten (turn clockwise) the adjust-
ing ring one notch on both sides. Continue with this
step until the rotating torque is 2.6 to 3.3 Nm (23 to
29 pound-inches).
RCPH10TLB362AAL 3
47365539 08/07/2012
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5. Secure the adjusting rings with the Allen screws,

torque the Allen screws to 10 Nm (88.5 pound
inches).
RCPH10TLB527AAL 4
Next operation:
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Differential - Install - Pinion shaft seal installation - 580SN-WT and

590SN only
1. Use seal driver, 380002432, and drive the seal into
the cover. The lips on the seal must be toward the
inside of the cover.
RCPH10TLB366AAL 1
RCPH10TLB365AAL 2
3. Put the CAS2369 Pinion Spline Seal Protector on the

pinion gear shaft.
RCPH10TLB536AAL 3
47365539 08/07/2012
27.106 / 85
stall the cover on the center section.
RCPH10TLB543AAL 4
5. Use a soft-face hammer to seat the seal.
RCPH10TLB537AAL 5
6. Remove the CAS2369 from the pinion gear shaft.
Next operation:
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Differential - Install - Carrier Installation - 580SN-WT and 590SN only

1. Apply a coat of Loctite 510 to the mating surface for
the carrier.
RCPH10TLB534AAL 1
2. Attach lifting equipment to the carrier and place onto

the axle housing.
RCPH10TLB529AAL 2

away from the axle housing, remove the lifting at-
tached equipment from the differential housing. Use
a soft-face hammer and tap the carrier until the dowel
pins are fully seated.
RCPH10TLB530AAL 3
4. Use Loctite 638 on carrier bolts and torque the short

carrier bolts to 169 Nm (124.5 pound-feet). Torque
the long carrier bolts to 80 Nm (59 pound-feet).
RCPH10TLB533AAL 4
47365539 08/07/2012
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NOTE: DO NOT use any thread locking compound on these bolts.
Next operation:
Differential - Check (27.106)
47365539 08/07/2012
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Differential - Check - Checking the differential lock - 580SN-WT

and 590SN only
1. Connect a hand pump and gauge to the fitting on the
differential lock. Have someone turn the wheel hub
as slight pressure is applied to the hand pump. If the
differential lock is working correctly the wheel hub
will become hard to turn and the wheel hub on the
opposite side of the axle will turn at the same time.
NOTE: Make sure the air is removed from the brake system when the axle is installed on the machine.
47365539 08/07/2012
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Index

Differential - Adjust - Differential bearing preload adjustment - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . 45
Differential - Adjust - Differential bearing preload adjustment - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . 83
Differential - Adjust - Pinion gear backlash adjustment - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Differential - Adjust - Pinion gear backlash adjustment - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . 82
Differential - Assemble - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Differential - Assemble - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Differential - Check - Checking the differential lock - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Differential - Check - Checking the differential lock - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Differential - Disassemble - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Differential - Disassemble - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Differential - Exploded view - Differential - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Differential - Exploded view - Differential - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Differential - Exploded view - Differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Differential - Exploded view - Ring and pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Differential - Install - Carrier Installation - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Differential - Install - Carrier installation - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Differential - Install - Differential lock for installation - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Differential - Install - Differential lock fork installation - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Differential - Install - Differential lock housing and piston - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Differential - Install - Pinion shaft seal installation - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Differential - Install - Pinion shaft seal installation - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Differential - Remove - Carrier removal - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Differential - Remove - Carrier removal 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Differential - Remove - Differential lock for removal - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Differential - Remove - Differential lock fork removal - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
47365539 08/07/2012
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Planetary and final drives - 120
580N
580SN WT
580SN
590SN
47365539 08/07/2012
27.120 / 1
Contents
FUNCTIONAL DATA
Wheel hub
Exploded view - Wheel hub and final reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Wheel hub
Disassemble - Wheel hub and brakes - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Inspect - Wheel hub and brakes - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assemble - Wheel hub and brakes - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassemble - Wheel hub and brakes - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Inspect - Wheel hub and brakes - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Assemble - Wheel hub and brakes - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
47365539 08/07/2012
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CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 270 Wheel hub - Assemble - Wheel hub and brakes - 580N and 27.120 / 31
580SN only
47365539 08/07/2012
27.120 / 3
Rear axle system - Planetary and final drives
Wheel hub - Exploded view - Wheel hub and final reduction unit
Wheel hub and final reduction unit
(1) Ring nut

(2) Inner bearing
(3) O-ring
(4) Ring gear (not serviced)
(5) Bleeder valve
(6) Shipping plug
(7) Hub
(8) Spacer
(9) Outer bearing
(10) Cassette seal
(11) Pad
(12) Wheel flange
(13) Snap ring
(14) Gear
(15) Snap ring
(16) Bearing
(17) Planetary carrier
(18) Bolt
(19) Stud
47365539 08/07/2012
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RCPH10TLB12GAL 1
47365539 08/07/2012
27.120 / 5
Wheel hub - Disassemble - Wheel hub and brakes - 580N and

580SN only
1. Remove the axle vent to relieve any pressure inside
of the axle.
RCPH10TLB384AAL 1
2. Place an oil receptacle under the outer housings of

the axle and drain the oil.
RCPH10TLB385AAL 2
3. Place an oil receptacle under the differential carrier

and drain the oil.
RCPH10TLB376AAL 3
47365539 08/07/2012
27.120 / 6
4. Remove all but two of the cap screws.

NOTICE: Large amounts of Loctite were used during as-
sembly, remove cap screws slowly. If screw binds, turn
back in and then back out.
RCPH10TLB382AAL 4
5. Insert three long dowel rods for in vehicle service or

two short dowel rods for bench service.
RCPH10TLB393AAL 5
6. Remove the remaining cap screws.
RCPH10TLB394AAL 6
7. Pry the hub from the axle using slots.
RCPH10TLB395AAL 7
47365539 08/07/2012
27.120 / 7
8. Slowly pull hub away from axle, make sure that the
brake disks and plates stay with the hub.
RCPH10TLB396AAL 8
9. Pull the half shaft out with the hub and brakes.
RCPH10TLB397AAL 9
10. Place the hub, brakes and half shaft on a suitable

work bench.
RCPH10TLB398AAL 10
11. Stand the hub up, mark the reaction plat that was
against the axle housing. Remove the reaction and
brake disks.
NOTE: Keep brake surfaces in same relationship to each
other if being reused.
RCPH10TLB399AAL 11
47365539 08/07/2012
27.120 / 8
12. Remove the half shaft from the planetary gears.
RCPH10TLB311AAL 12
13. Left hand shaft is 807 mm (31.8 in) long and the right
hand shaft is 701 mm (27.6 in) long.
RCPH10TLB375AAL 13
14. Loosen and remove the shouldered bolts, and spring

washers from the brake self adjusters.
RCPH10TLB312AAL 14
15. Check springs and shouldered bolt for damage. If

brakes are being replaced, replace springs and bolts
with kit.
RCPH10TLB401AAL 15
47365539 08/07/2012
27.120 / 9
RCPH10TLB314AAL 16
17. Remove the self adjuster. If brakes are being re-

placed replace adjusters.
NOTE: Once removed the self adjusters spring clips must
be replace with genuine parts, DO NOT use after market
parts.
RCPH10TLB315AAL 17
18. Place the tapered end of the self adjuster (1) on tool
380002435.
RCPH10TLB404AAL 18
19. Place the 380002435 driver tool (1) onto the self ad-
juster (2) and drive the spring clips (3) off of the ad-
juster.
RCPH10TLB405AAL 19
47365539 08/07/2012
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20. Inspect adjuster bushing for wear.
RCPH10TLB406AAL 20
21. Use two acceptable flat bars and evenly pry the brake
piston up from the hub.
RCPH10TLB316AAL 21
22. Remove the piston from the hub.
RCPH10TLB317AAL 22
23. Remove the inner cylinder.
RCPH10TLB421AAL 23
47365539 08/07/2012
27.120 / 11
24. If the cylinder remained in the housing, use a suitable

pry bar to remove the cylinder.
RCPH10TLB318AAL 24
25. If the machine has high work hours, remove and dis-
card the outer brake piston O-ring.
RCPH10TLB415AAL 25
card the inner brake piston O-ring.
RCPH10TLB416AAL 26
card the brake cylinder O-ring.
RCPH10TLB418AAL 27
47365539 08/07/2012
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28. Remove and discard the hub O-ring.
RCPH10TLB319AAL 28
29. Attach suitable lifting equipment to the planetary

gears.
RCPH10TLB320AAL 29
30. Locate the snap ring slot and place snap ring pliers
in slot.
RCPH10TLB334AAL 30
31. Hold the snap ring open. Carefully raise and remove
the planetary set from the hub. Release the snap ring
after the end of the wheel flange shaft is cleared.
RCPH10TLB321AAL 31
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27.120 / 13
32. Remove planetary gear retainer snap rings.
RCPH10TLB322AAL 32
33. Remove planetary gear and bearings.
RCPH10TLB323AAL 33
34. Place the wheel end in a suitable press and lock the
wheel hub so it can will not turn.
NOTICE: Do not use excessive force, otherwise damage
to the hub will occur.
RCPH10TLB326AAL 34
35. Loosen the wheel flange nut using a ring nut socket
tool 380002434 and a torque multiplier.
RCPH10TLB320AAL 35
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27.120 / 14
36. Remove ring nut from wheel hub.
RCPH10TLB423AAL 36
37. Do not press directly against the sun gear pad.
RCPH10TLB329AAL 37
38. Place the wheel hub in a press.
RCPH10TLB330AAL 38
39. Press the wheel flange from the wheel hub.
RCPH10TLB331AAL 39
47365539 08/07/2012
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40. Attach lifting equipment to hub housing and remove

from the wheel flange.
RCPH10TLB332AAL 40
41. Remove the inner bearing race.
RCPH10TLB425AAL 41
42. Remove the cassette seal.
RCPH10TLB426AAL 42
43. Remove the outer race.
RCPH10TLB429AAL 43
47365539 08/07/2012
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44. Remove spacer from wheel flange.
RCPH10TLB431AAL 44
45. To remove the inner bearing, use a die grinder to cut

the roller retainer and race. Use a chisel in the slot
cut in the race to crack the race, remove the race.
RCPH10TLB430AAL 45
Next operation:
Wheel hub - Inspect (27.120)
47365539 08/07/2012
27.120 / 17
Wheel hub - Inspect - Wheel hub and brakes - 580N and 580SN only
2. Discard all seals and O-rings.
you find any of these defects, you must install new
wheel bearings and bearing cups.
The planetary shaft bushings are not sold separately.
If a shaft bushing is damaged, you must use a new
carrier.
5. Inspect the teeth on the planetary gears, the half
shaft, and the ring gear for wear, pitting, scoring, and
6. Inspect the needle bearings for the planetary gears
for flat areas, pitting, scoring, and other damage. If
you find any of these defects, use new parts as re-
quired.
7. Inspect the brake disks and reaction plates for pitting,
scoring, excessive surface wear, and other damage.
8. Inspect brake pistons and cylinders for scaring on
sliding surfaces, brake pistons for pitting, scoring,
and excessive surface wear at brake contact point.
Use new pars as required.
9. Replace O-rings on brake cylinders and pistons.
NOTICE: Use only genuine parts. DO NOT use after market O-rings, they will fail.
Next operation:
Wheel hub - Assemble (27.120).
47365539 08/07/2012
27.120 / 18
Wheel hub - Assemble - Wheel hub and brakes - 580N and 580SN
only
When installing new brake discs, soak the new brake discs in oil for 24 hours prior to installation.
1. If the outer bearing cups were removed, use an Uni-

versal Bearing Cup Installer or a suitable tool to in-
stall the bearing cups.
NOTE: The illustration shows the cassette seal installed,
the cassette seal will be installed during a later step.
RCPH10TLB427AAL 1
2. If the inner bearing cups were removed, use an Uni-

versal Bearing Cup Installer or other acceptable tool
to install the bearing cups.
RCPH10TLB428AAL 2
NOTICE: Caution possible component damage. The word

"OUTSIDE" on the hub seal must face outward. Do not
push the hub seal further than required during the instal-
lation. Failure to comply may result in damage to the hub
seal.
3. Attach the 380002431 hub seal installer with handle
to install the hub seal. Push only until the hub seal
makes contact with the shoulder inside the hub.
RCPH10TLB333AAL 3
47365539 08/07/2012
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4. Install the outer wheel flange bearing with a suitable

driver.
RCPH10TLB430AAL 4
5. Install spacer on wheel flange.
RCPH10TLB431AAL 5
6. Clean all sealing surfaces with an alcohol based

cleaner, if any oil residue is on sealing surfaces the
seal will leak.
NOTICE: Caution possible component damage. Install the
hub straight onto the wheel flange, damage to seal can
occur if angled. DO NOT use excess force to seat hub onto
wheel flange. Failure to comply may damage the wheel
flange of hub seal.
7. Attach lifting equipment to hub and carefully install
onto wheel flange.
RCPH10TLB332AAL 6
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8. Install inner bearing with a suitable driver and the ring

nut.
RCPH10TLB423AAL 7
9. Attach the ring nut socket, 380002434, and torque to

1000 N·m (738 lb ft).
NOTE: The use of a torque multiplier as shown is accept-
able.
RCPH10TLB328AAL 8
10. With a suitable driver, press the planetary gears onto

the planet carrier.
RCPH10TLB324AAL 9
11. Install the retaining snap rings on the carrier.
RCPH10TLB325AAL 10
47365539 08/07/2012
27.120 / 21
12. Attach lifting equipment to the planetary set and

lower into the hub.
13. Engage the locking ears on the planetary carrier to
secure the ring nut.
RCPH10TLB424AAL 11
14. Hold the snap ring open and lower the planetary as-
sembly into position.
RCPH10TLB334AAL 12
15. Make sure that the snap ring is fully closed, the two
tips touch before removing the lifting equipment.
RCPH10TLB335AAL 13
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16. Install a new O-ring on the hub.
RCPH10TLB336AAL 14
17. Apply hydraulic oil to the brake cylinder O-ring.
RCPH10TLB419AAL 15
18. Apply hydraulic oil to the inner O-ring of the brake

piston. Press the brake cylinder into the brake piston.
RCPH10TLB420AAL 16
19. Apply hydraulic oil to the outer O-ring of the brake

piston.
RCPH10TLB422AAL 17
47365539 08/07/2012
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20. Apply hydraulic oil to the brake cavity of the hub

housing.
RCPH10TLB337AAL 18
NOTE: Use brake pins as guides.

21. Place the brake piston and cylinder onto the hub.
RCPH10TLB417AAL 19
22. Tighten the three shoulder bolts to pull the brake pis-
ton and cylinder into the hub.
RCPH10TLB339AAL 20
23. Place the tapered edge of the brake adjuster into the
depth setting tool, part of tool kit 380002435.
RCPH10TLB407AAL 21
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27.120 / 24
24. Place aligning tool into brake adjuster tool, part of

tool kit 380002435.
RCPH10TLB408AAL 22
NOTE: For ease of installation, look at the inside of the

adjuster ring, place tapered end down.
25. Place the first adjuster ring onto aligning tool.
RCPH10TLB409AAL 23
26. Place the second adjuster ring onto aligning tool with
the slot at 90° from the slot of the first ring.
RCPH10TLB410AAL 24
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27.120 / 25
27. Place the third adjuster ring onto aligning tool with
RCPH10TLB411AAL 25
28. Place the fourth adjuster ring onto aligning tool with
RCPH10TLB412AAL 26
29. Place driver tool onto aligning tool, driver part of tool
kit 380002435.
RCPH10TLB413AAL 27
30. Drive the rings onto the adjuster until they are seated
against the depth setting tool.
RCPH10TLB414AAL 28
47365539 08/07/2012
27.120 / 26
31. Insert the adjuster into the brake piston, make sure
that the chaffered side is up.
RCPH10TLB403AAL 29
32. Make sure the tabs of the snap ring face the adjuster
during installation.
RCPH10TLB490AAL 30
33. Install the snap ring into the self adjuster bore.
RCPH10TLB314AAL 31
34. Make sure the snap ring fully engages the groove in
the brake piston.
RCPH10TLB338AAL 32
47365539 08/07/2012
27.120 / 27
35. Place spring washers onto the shoulder bolt facing

as shown.
RCPH10TLB400AAL 33
36. Hand tighten the shouldered bolt until seated into

adjuster, spring washers can become bound on the
shoulder of the bolt and be damaged.
RCPH10TLB402AAL 34
37. Torque shoulder bolts to 16 N·m (142 lb in).
RCPH10TLB313AAL 35
38. Put the half shaft (1) and brake separator plate pins
(2) into the axle housing.
RCPH10TLB473AAL 36
47365539 08/07/2012
27.120 / 28
39. Using the reference mark made during disassembly,

place the thinner of the two inner brake separator
plate into the axle housing.
RCPH10TLB474AAL 37
40. Place the inner brake disc onto the half shaft, do not
damage any of the splines or teeth.
RCPH10TLB475AAL 38
NOTE: For the 580N there is only one brake disc, for all Super N models there are two brake discs.
41. Install the second brake separator, SN models only.
RCPH10TLB476AAL 39
NOTE: The thicker of the two separator plates is used here.
47365539 08/07/2012
27.120 / 29
42. Place the outer brake disc onto the half shaft, do not
RCPH10TLB477AAL 40
43. Make sure the slots of the inner and outer brake discs
are aligned with each other.
RCPH10TLB471AAL 41
44. Install dowel rods into axle housing, two short rods
for bench repair, three long for in vehicle repair.
RCPH10TLB472AAL 42
NOTE: Care needs to be taken that the self adjusters are

not damaged by falling plates or by hitting them on the
housing when bringing hub into position.
47365539 08/07/2012
27.120 / 30
45. Attach lifting equipment to hub assembly and guide

onto dowel rods.
RCPH10TLB478AAL 43
NOTE: The input shaft for the differential may need to be

turned in order to align the splines on the half shaft sun
gear and the planetary gears.
46. Wrap a piece of rope around the axle shaft and lift
the shaft into the planetary gears while pushing the
hub onto the axle. Remove the rope once the axle is
in the planetary gears.
RCPH10TLB479AAL 44
47. Apply LOCTITE® 270 to the threads of the bolts and

systematically tighten the bolts to a torque to 226
N·m (167 lb ft).
RCPH10TLB383AAL 45
48. Install and tighten drain plugs.

49. Fill the axle with oil.
Next operation:
47365539 08/07/2012
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Wheel hub - Disassemble - Wheel hub and brakes - 580SN-WT and

590SN only
of the axle.
RCPH10TLB384AAL 1

RCPH10TLB385AAL 2

and drain the oil.
RCPH10TLB376AAL 3
47365539 08/07/2012
27.120 / 32
RCPH10TLB382AAL 4
NOTE: Large amounts of Loctite was used during assembly, remove cap screws slowly. If screw binds, turn back in
and then back out.
5. Insert dowel rods to guide the wheel hubs off.
RCPH10TLB393AAL 5
RCPH10TLB394AAL 6
47365539 08/07/2012
27.120 / 33
RCPH10TLB395AAL 7
RCPH10TLB396AAL 8
RCPH10TLB397AAL 9

work bench.
RCPH10TLB398AAL 10
47365539 08/07/2012
27.120 / 34
brake disks.
RCPH10TLB399AAL 11
NOTE: Keep brake surfaces in same relationship to each other if being reused.
RCPH10TLB311AAL 12
RCPH10TLB375AAL 13

RCPH10TLB312AAL 14
47365539 08/07/2012
27.120 / 35

with kit.
RCPH10TLB401AAL 15
RCPH10TLB314AAL 16

RCPH10TLB315AAL 17
NOTE: Once removed the self adjusters spring clips must be replace with genuine parts, DO NOT use after market
parts.
47365539 08/07/2012
27.120 / 36
18. Place the self adjuster on 3800002435.
RCPH10TLB404AAL 18
19. Place the driver 3800002435 onto self adjuster and

drive the spring clips from the adjuster.
RCPH10TLB405AAL 19
RCPH10TLB406AAL 20
21. Use an acceptable flat bars and pry the brake piston
up from the hub.
RCPH10TLB316AAL 21
47365539 08/07/2012
27.120 / 37
RCPH10TLB317AAL 22
RCPH10TLB421AAL 23
24. The cylinder may remain in the housing, use pry bar
and remove the cylinder.
RCPH10TLB318AAL 24
25. Remove and discard outer brake piston O-ring only

if machine has high hours.
RCPH10TLB415AAL 25
47365539 08/07/2012
27.120 / 38
26. Remove and discard inner brake piston O-ring only

RCPH10TLB416AAL 26
27. Remove and discard brake cylinder O-ring only if ma-

chine has high hours.
RCPH10TLB418AAL 27
28. Remove and discard the hub O-ring.
RCPH10TLB319AAL 28
29. Attach lifting equipment to the planetary gears.
RCPH10TLB320AAL 29
47365539 08/07/2012
27.120 / 39
30. Locate the snap ring slot and place snap ring pliers
in slot.
RCPH10TLB334AAL 30
31. Carefully raise the planetary set, hold the snap ring
open until it has cleared the end of the wheel flange
shaft.
RCPH10TLB321AAL 31
32. Remove planetary set from the hub.

33. Remove planetary gear retainer snap rings.
RCPH10TLB322AAL 32
34. Remove planetary gear and bearings.
RCPH10TLB323AAL 33
47365539 08/07/2012
27.120 / 40
35. Place the wheel end in a press and lock the wheel
hub so it can not turn.
RCPH10TLB326AAL 34
NOTE: Do not use excessive force.

36. Use ring nut socket, 380002434, a torque multiplier,
and loosen wheel flange ring nut.
RCPH10TLB327AAL 35
37. Remove ring nut from wheel hub.
RCPH10TLB423AAL 36
38. Do not press directly against the sun gear pad.
RCPH10TLB329AAL 37
47365539 08/07/2012
27.120 / 41
39. Place the wheel hub in a press.
RCPH10TLB330AAL 38
40. Press the wheel flange from the wheel hub.
RCPH10TLB331AAL 39
41. Attach lifting equipment to hub housing and remove

from the wheel flange.
RCPH10TLB332AAL 40
42. Remove the inner bearing race.
RCPH10TLB425AAL 41
47365539 08/07/2012
27.120 / 42
43. Remove the cassette seal.
RCPH10TLB426AAL 42
44. Remove the outer race.
RCPH10TLB429AAL 43
45. Remove spacer from wheel flange.
RCPH10TLB431AAL 44
46. To remove the inner bearing, use a die grinder to cut

the roller retainer and race. Use a chisel in the slot
cut in the race to crack the race, remove the race.
RCPH10TLB430AAL 45
Next operation:
47365539 08/07/2012
27.120 / 43
Wheel hub - Inspect (27.120)
47365539 08/07/2012
27.120 / 44
Wheel hub - Inspect - Wheel hub and brakes - 580SN-WT and 590SN
only
2. Discard all seals and O-rings.
you find any of these defects, you must install new
wheel bearings and bearing cups.
The planetary shaft bushings are not sold separately.
If a shaft bushing is damaged, you must use a new
carrier.
5. Inspect the teeth on the planetary gears, the half
shaft, and the ring gear for wear, pitting, scoring, and
6. Inspect the needle bearings for the planetary gears
for flat areas, pitting, scoring, and other damage. If
you find any of these defects, use new parts as re-
quired.
Use new pars as required.
NOTICE: Use only genuine parts. DO NOT use after market O-rings, they will fail.
Next operation:
Wheel hub - Assemble (27.120)
47365539 08/07/2012
27.120 / 45
Wheel hub - Assemble - Wheel hub and brakes - 580SN-WT and

590SN only
1. If the outer bearing cups were removed, use an
OEM-4185 Universal Bearing Cup Installer or other
acceptable tool to install the bearing cups.
RCPH10TLB427AAL 1
NOTE: The above photo shows the cassette seal installed, the cassette seal will be installed during a later step.
2. If the inner bearing cups were removed, use an
OEM-4185 Universal Bearing Cup Installer or other
acceptable tool to install the bearing cups.
RCPH10TLB428AAL 2
NOTICE: The words “OUTSIDE” on the hub seal must be facing out.
3. Use the 380002431 hub seal installer with handle
to install the hub seal. Push only until the hub seal
makes contact with the shoulder inside the hub. Con-
tinued pushing can damage the hub seal.
RCPH10TLB333AAL 3
47365539 08/07/2012
27.120 / 46
4. Install the outer wheel flange bearing with a suitable

driver.
RCPH10TLB430AAL 4
5. Install spacer on wheel flange.
RCPH10TLB431AAL 5
6. Clean all sealing surfaces with an alcohol based

cleaner, if any oil residue is on sealing surfaces the
seal will leak.
7. Attach lifting equipment to hub and carefully install
onto wheel flange.
RCPH10TLB332AAL 6
NOTE: Use care and install the hub straight onto the wheel flange, damage to seal can occur if angled. DO NOT use
excess force to seat hub onto wheel flange.
47365539 08/07/2012
27.120 / 47
8. Install inner bearing with a suitable driver, install ring

nut.
RCPH10TLB423AAL 7
NOTE: The ring nut can be installed with either side up or down.
9. Use ring nut socket, 380002434, torque ring nut to
1000 Nm (737.5 pound-feet).
RCPH10TLB328AAL 8
NOTE: The use of a torque multiplier as shown is acceptable.

10. Use a suitable driver and press the planetary gears
onto the planet carrier.
RCPH10TLB324AAL 9
47365539 08/07/2012
27.120 / 48
11. Install the retaining snap rings on the carrier.
RCPH10TLB325AAL 10
12. Attach lifting equipment to planetary set and lower

into hub.
13. During installation the locking ears on the planetary
carrier must engage the ring nut as shown.
RCPH10TLB424AAL 11
14. Hold the snap ring open and lower the planetary as-
sembly into position.
RCPH10TLB334AAL 12
47365539 08/07/2012
27.120 / 49
15. Make sure that the snap ring is fully closed, two tips
touch, remove lifting equipment.
RCPH10TLB335AAL 13
16. Install a new O-ring onto the hub.
RCPH10TLB336AAL 14
17. Use hydraulic oil to lubricate the brake cylinder

O-ring.
RCPH10TLB419AAL 15
18. Use hydraulic oil to lubricate the inner O-ring of the

brake piston, press the brake cylinder into the brake
piston.
RCPH10TLB420AAL 16
47365539 08/07/2012
27.120 / 50
19. Use hydraulic oil to lubricate the outer O-ring of the

brake piston.
RCPH10TLB422AAL 17
20. Use hydraulic oil to lubricate the brake cavity of the

hub housing.
RCPH10TLB337AAL 18
RCPH10TLB417AAL 19
NOTE: Use brake pins for guides.

22. Use the three shouldered bolts and washers to pull
the brake piston and cylinder into the hub.
RCPH10TLB339AAL 20
47365539 08/07/2012
27.120 / 51
23. Place the brake adjuster with tapered edge facing up

into depth setting tool, part of tool kit 380002435.
RCPH10TLB407AAL 21

tool kit 380002435.
RCPH10TLB408AAL 22
RCPH10TLB409AAL 23
NOTE: For ease of installation, look at the inside of the adjuster ring, place tapered end down.
RCPH10TLB410AAL 24
47365539 08/07/2012
27.120 / 52
RCPH10TLB411AAL 25
RCPH10TLB412AAL 26
kit 380002435.
RCPH10TLB413AAL 27
RCPH10TLB414AAL 28
47365539 08/07/2012
27.120 / 53
RCPH10TLB403AAL 29
32. Make sure the tips of the snap ring face the adjuster
RCPH10TLB490AAL 30
RCPH10TLB314AAL 31
34. Make sure the snap ring fully engages the grove in
the brake piston.
RCPH10TLB338AAL 32
47365539 08/07/2012
27.120 / 54
35. Place spring washers onto shouldered bolt facing as

shown.
RCPH10TLB400AAL 33

RCPH10TLB402AAL 34
37. Torque shouldered bolts to 16 Nm (141.4 pound-

inches).
RCPH10TLB313AAL 35
38. Put the half shaft and brake separator plate pins into
the axle housing.
RCPH10TLB473AAL 36
47365539 08/07/2012
27.120 / 55

place the inner brake separator plate into the axle
housing.
RCPH10TLB474AAL 37
NOTE: The thinner of the two separator plates is used here.

NOTICE: If using new brake disks they must be soaked in oil for 24 hours prior to installation.
40. Place the inner brake disk onto the half shaft, do not
RCPH10TLB475AAL 38
NOTE: For the 580N there is only one brake disk, for all Super N models there are two brake disks.
RCPH10TLB476AAL 39
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42. Place the outer brake disk onto the half shaft, do not
RCPH10TLB477AAL 40
43. Make sure the slots of the inner and outer brake disks
RCPH10TLB471AAL 41
RCPH10TLB472AAL 42

onto dowel rods.
RCPH10TLB478AAL 43
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NOTE: Care must be taken so the self adjusters are not damaged by falling plates or by hitting them on the housing
when bringing the hub into position.
46. Use a piece of rope and lift the axle shaft into the
planetary gears while pushing the hub onto the axle.
RCPH10TLB479AAL 44
NOTE: The input shaft for the differential may need to be turned in order to align the splines on the half shaft sun gear
and the planetary gears.
47. Use Loctite 270 on thread of the bolts and torque to
226 Nm (166.5 pound-feet).
RCPH10TLB383AAL 45
48. Install and tighten drain plugs.

49. Fill the axle with oil, see specification for quantity and
type.
Next operation:
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Index

Wheel hub - Assemble - Wheel hub and brakes - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Wheel hub - Assemble - Wheel hub and brakes - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Wheel hub - Disassemble - Wheel hub and brakes - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Wheel hub - Disassemble - Wheel hub and brakes - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wheel hub - Exploded view - Wheel hub and final reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wheel hub - Inspect - Wheel hub and brakes - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wheel hub - Inspect - Wheel hub and brakes - 580SN-WT and 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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PRINTED IN U.S.A.
47365539 08/07/2012
EN
SERVICE MANUAL
Brakes and controls
580N
580SN WT
580SN
590SN
47365539 08/07/2012
33
Contents
Brakes and controls - 33
Parking brake / Parking lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.110

580N , 580SN WT , 580SN , 590SN
Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.202

580N , 580SN WT , 580SN , 590SN
47365539 08/07/2012
33
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® Brakes - Disassemble 33.202 / 14
Loctite® 270 Brakes - Assemble 33.202 / 30
47365539 08/07/2012
33
47365539 08/07/2012
33
Parking brake / Parking lock - 110
580N
580SN WT
580SN
590SN
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33.110 / 1
Contents
SERVICE
Parking brake disks

Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Brakes and controls - Parking brake / Parking lock
Parking brake disks - Disassemble
NOTE: Some of the following images may not represent

your transmission, the procedures are the same.
1. Park the machine on a level surface, apply the park-
ing brake.
2. Block the wheels to keep the machine from moving.
3. Drain the transmission.
4. Remove the rear drive shaft.
5. Loosen the flange bolt.
RCPH10TLB596AAL 1
6. Remove the flange bolt and washer.
RCPH10TLB868AAL 2
7. Remove the O-ring and flange.

NOTE: The transmission was removed from the machine
for clarity only, it is not necessary to remove the transmis-
sion.
RCPH10TLB869AAL 3
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33.110 / 3
8. Loosen brake housing bolts.
RCPH10TLB871AAL 4
9. Remove bolts (A), and alternately loosen bolts (B) to

release the load of bellville washer.
NOTE: Housing is under spring pressure, failure to fol-
low instructions will result in serious injury and damage to
equipment.
RCPH10TLB594AAL 5
10. Remove the brake cover from the transmission.
RCPH10TLB872AAL 6
11. Remove and discard the O-ring.
RCPH10TLB873AAL 7
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12. Remove back plate.
RCPH10TLB874AAL 8
13. Remove the springs and remove the friction disc.
RCPH10TLB875AAL 9
14. Remove the reaction plates.
RCPH10TLB876AAL 10
15. Remove the hub.
RCPH10TLB877AAL 11
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RCPH10TLB599AAL 12
17. Remove and discard the O-rings and backup ring

from the retaining plate.
RCPH10TLB600AAL 13
18. Use CAS2379 to compress the bellville washers, re-

move the retaining ring.
RCPH10TLB601AAL 14
19. Remove the piston from the brake housing.
RCPH10TLB602AAL 15
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20. Remove and discard the O-rings and backup rings

from the piston.
RCPH10TLB603AAL 16
21. Remove the bellville washers from the brake hous-

ing.
RCPH10TLB604AAL 17
22. Remove the seal from the brake housing.
RCPH10TLB605AAL 18
23. Remove and discard the O-ring from the brake hous-
ing.
RCPH10TLB606AAL 19
Next operation:
Parking brake disks - Inspect (33.110)
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Parking brake disks - Inspect

Prior operation:
Parking brake disks - Disassemble (33.110)

3. Inspect the bellville washer for cracking and exces-
sive surface wear at contact points. Use new parts
as required.
4. Inspect brake pistons and housing for scaring on slid-
ing surfaces, brake pistons for pitting, scoring, and
excessive surface wear at brake contact point. Use
new parts as required.
NOTE: Use only genuine parts. DO NOT use after market
O-rings, they will fail.
Next operation:
Parking brake disks - Assemble (33.110)
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33.110 / 8
Parking brake disks - Assemble

Prior operation:
Parking brake disks - Inspect (33.110)
1. Install a new O-ring on the brake housing.
RCPH10TLB607AAL 1
2. Install the bellville washers as shown.
RCPH10TLB595AAL 2
3. Install the backup ring, install the seal ring.
RCPH10TLB608AAL 3
NOTE: Make sure that the seal ring does not twist during installation.
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4. Lubricate the piston seals with transmission fluid, in-

stall the piston into the brake housing.
RCPH10TLB602AAL 4
5. Use CAS2379 and compress the bellville washers,

install the retaining ring.
NOTICE: Make sure the retainer is properly seated before
removing spring compressor.
RCPH10TLB601AAL 5
6. Install new O-rings and backup ring in the retaining

plate.
RCPH10TLB600AAL 6
7. Lubricate the O-rings on the retaining plate, install

the plate into the brake housing.
RCPH10TLB599AAL 7
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RCPH10TLB877AAL 8
RCPH10TLB876AAL 9

RCPH10TLB875AAL 10
RCPH10TLB874AAL 11
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RCPH10TLB873AAL 12
RCPH10TLB872AAL 13

sion. Torque the bolts to 50 N·m (37 lb ft).
RCPH10TLB871AAL 14
RCPH10TLB869AAL 15
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RCPH10TLB868AAL 16
17. Torque bolt to 139 N·m (103 lb ft).
RCPH10TLB870AAL 17
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Parking brake disks - Check

1. Block the wheels of the vehicle to prevent any move-
ment.
2. Remove the floor plates in the cab to gain access to
the brake solenoid.
RCPH10TLB597AAL 1
3. Remove the solenoid mounting bolts, remove the so-

lenoid from the transmission.
RCPH10TLB598AAL 2
4. Turn the solenoid 90° and torque the solenoid to 20

N·m (14.8 lb ft). Pump grease into the grease fitting
until the brake releases.
NOTE: Do not use excess pressure or damage can be done to internal components.
Activate
5. Slowly remove the bolts from the brake solenoid to
release the pressure.
NOTE: Do not unscrew the grease fitting to release the
pressure.
6. Clean excess grease from the solenoid and trans-
mission housing.
7. Install new O-rings on the transmission.
8. Install the solenoid on the transmission, torque the
solenoid to 20 N·m (14.8 lb ft).
9. Activate and release the brake several times to re-
move excess grease from the system.
10. Change the transmission filter, check the oil level in
the transmission, add oil as required.
11. Replace the floor plates in the cab.
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Parking brake disks - Test

Parking brake
2. Lock the brake pedals with the brake pedal locking
pin.
NOTICE: Be prepared to stop the machine in case of sud-
den movement.
3. Place the gear selector in 3rd gear on manual trans-
mission machines. For power shift transmission,
place the auto/manual switch to manual, select 3rd
gear on the FNR lever.
4. With engine running at low idle place the selector
lever in F position.
5. Raise engine RPM to 1500 RPM, the machine should
not move.
6. Repeat the procedure with the selector in the R po-
sition.
NOTE: If the machine moves the parking brake will have
to be repaired, see Brakes - Disassemble (33.202).
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Index

Parking brake disks - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Parking brake disks - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Parking brake disks - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Parking brake disks - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Parking brake disks - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Hydraulic service brakes - 202
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
Hydraulic service brakes

Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA

Exploded view - Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Brakes
Exploded view - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exploded view - Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SERVICE

Adjust - Brake pedal height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Brakes
Remove - Removing air from the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Adjust - Brake pedal height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
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CONSUMABLES INDEX
Consumable IU PAGE
Loctite® Brakes - Disassemble 33.202 / 14
Loctite® 270 Brakes - Assemble 33.202 / 30
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Brakes and controls - Hydraulic service brakes
Hydraulic service brakes - General specification

Rear Axle
580N, 580SN
MAT3510
580SN-WT, 590SN
Type of Fluid. Wet Brake/Transmission Lubricant - SAE 80W140
MAT3510
Axle Special Torques

Wheel Nuts Special Torques

Initial torque 136 N·m (100.3 lb ft)
2nd torque 271 N·m (199.9 lb ft)
NOTE: Turn nuts an additional 30 ° after second torque.
Transmission Special Torques

Park brake housing 50 N·m (36.9 lb ft)
Output flange bolt 139 N·m (102.5 lb ft)
Park brake solenoid 20 N·m (14.8 lb ft)
Hydraulic service brakes - Special tools
RCPH10TLB378AAL 1
Self adjusting brake tools 380002435
NOTE: Part of rear axle service tools.
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33.202 / 4
RCPH10TLB043ABL 2
CAS-2379 input shaft holder and spring compressor
NOTE: Part of transmission service tools.
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Hydraulic service brakes - Exploded view - Brake pedal
RCPH10TLB033GAL 1
1. Bolt 7. Bolt 13. Height adjusting bolt

2. Pivot pin 8. 60 mm (2.36 in) 14. Spring
3. Spacer 9. 27 mm (1.06 in) 15. Brake light switch
4. Shim 10. Clevis pin 16. Right pedal
5. Self locking nut 11. Cotter pin 17. Left pedal
6. Bushings 12. Master cylinder 18. Pedal locking pin
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Brakes - Exploded view - Brakes

Rear brakes
1. Lock ring
2. Self adjusting kit
3. Brake piston
4. O-ring
5. O-ring
6. Brake cylinder
7. O-ring
8. Pin
9. Hub
10. Axle housing
11. Pin
12. Half shaft
13. Brake plate
14. Brake disk
15. Brake plate
16. Brake disk
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RCPH10TLB8GAL 1
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33.202 / 9
Brake master cylinder - Exploded view - Brake pedal
RCPH10TLB033GAL 1
1. Bolt 7. Bolt 13. Height adjusting nut

2. Pivot pin 8. 60 mm (2.36 in) 14. Spring
3. Spacer 9. 27 mm (1.06 in) 15. Brake light switch
4. Shim 10. Clevis pin 16. Right pedal
5. Self locking nut 11. Cotter pin 17. Left pedal
6. Bushings 12. Master cylinder 18. Pedal locking pin
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Hydraulic service brakes - Adjust - Brake pedal height adjustment

1. Using the adjustment bolts, adjust the LH and RH
pedals to 90 - 92 mm (3.54 - 3.62 in).
2. Adjust the master cylinder push rods in order to
achieve 1 - 3 mm (0.039 - 0.118 in) of free play
measured at the pedal pad.
RCPH10TLB591AAL 1
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Brakes - Remove - Removing air from the brake system

NOTE: Two people are required to perform this procedure, one to actuate the master cylinder and the other to open
and close the brake bleeder valve on the rear axle.
1. Raise the machine up with the stabilizers at full
height. Support back end of machine with appropri-
ate stands.
2. Remove rear wheels.
3. Attach clear brake bleeding hoses to the LH and RH
bleeding ports.
4. Loosen LH and RH brake bleeders.
5. Start engine and leave at low idle. Ensure that the
transmission oil level is correct.
6. Fully stroke both pedals together 15 times.
7. Fully stroke the RH pedal individually until clear
columns of oil without air bubbles are observed in
the clear plastic tube. Close RH bleeder.
8. Repeat for LH side.
9. Verify that the park brake is not engaged. Ensure
that the service brakes will stop both rear wheels with
the tractor in 2nd gear at 1500 RPM with the brake
pedal pads 30 mm (1.181 in) above the top of the
floor plate 37 mm (1.457 in) above the top of the floor
plate for units that will be equipped with a floormat).
If the service brakes do not stop the wheels as noted
above, open each bleeder and repeat steps 7 and 8
until columns of oil without air bubbles are observed
in the LH and RH bleeder hoses. Verify that the ser-
vice brakes hold the tractor in 2nd gear at 1500 RPM
as noted above.
10. Shut engine off.
11. Remove brake bleeding hoses.
12. Replace covers on LH and RH brake bleeders.
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Brakes - Disassemble
1. Park the machine on a level surface, apply the park-
ing brake.
2. Raise the rear tires off of the ground, support the
machine with suitable stands.
3. Remove the tires from the machine.
4. Remove the mounting bolts for the brake hose guard,
disconnect the brake hose. Plug the hose and cap
the fitting.
RCPH10TLB066AAL 1

of the axle.
RCPH10TLB384AAL 2

RCPH10TLB385AAL 3
47365539 08/07/2012
33.202 / 13

and drain the oil.
RCPH10TLB376AAL 4

NOTE: Large amounts of LOCTITE® was used during as-
sembly, remove cap screws slowly. If screw binds, turn
back in and then back out.
RCPH10TLB382AAL 5
9. Insert 3 long dowel rods, (tool number), for in vehicle

service or two short dowel rods, (tool number), for
bench service.
RCPH10TLB393AAL 6
RCPH10TLB394AAL 7
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33.202 / 14
RCPH10TLB395AAL 8
RCPH10TLB396AAL 9
RCPH10TLB397AAL 10

work bench.
RCPH10TLB398AAL 11
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33.202 / 15
brake disks.
NOTE: Keep brake surfaces in same relationship to each
other if being reused.
RCPH10TLB399AAL 12
RCPH10TLB311AAL 13
RCPH10TLB375AAL 14

RCPH10TLB312AAL 15
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33.202 / 16

with kit.
RCPH10TLB401AAL 16
RCPH10TLB314AAL 17

NOTE: Once removed the self adjusters spring clips must
be replace with genuine parts, DO NOT use after market
parts.
RCPH10TLB315AAL 18
22. Place the self adjuster on (tool number).

NOTE: Place the tapered end of the self adjuster into (tool
number).
RCPH10TLB404AAL 19
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23. Place the driver (tool number) onto self adjuster and
drive the spring clips from the adjuster.
RCPH10TLB405AAL 20
RCPH10TLB406AAL 21
25. Use an acceptable flat bars and pry the brake piston
up from the hub.
RCPH10TLB316AAL 22
RCPH10TLB317AAL 23
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RCPH10TLB421AAL 24
28. The cylinder may remain in the housing, use pry bar
and remove the cylinder.
RCPH10TLB318AAL 25
29. Remove and discard outer brake piston O-ring only

RCPH10TLB415AAL 26
30. Remove and discard inner brake piston O-ring only

RCPH10TLB416AAL 27
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31. Remove and discard brake cylinder O-ring only if ma-

chine has high hours.
RCPH10TLB418AAL 28
32. Remove and discard the hub o-ring.
RCPH10TLB319AAL 29
Next operation:
Brakes - Inspect (33.202)
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Brakes - Inspect
Prior operation:
Brakes - Disassemble (33.202)

NOTE: Use only genuine parts. DO NOT use after market
O-rings, they will fail.
Next operation:
Brakes - Assemble (33.202)
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Brakes - Assemble
Prior operation:
Brakes - Inspect (33.202).
1. Install a new O-ring onto the hub.
RCPH10TLB336AAL 1
2. Use hydraulic oil to lubricate the brake cylinder

O-ring.
RCPH10TLB419AAL 2
3. Use hydraulic oil to lubricate the inner O-ring of the

brake piston, press the brake cylinder into the brake
piston.
RCPH10TLB420AAL 3
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4. Use hydraulic oil to lubricate the outer O-ring of the

brake piston.
RCPH10TLB422AAL 4
5. Use hydraulic oil to lubricate the brake cavity of the

hub housing.
RCPH10TLB337AAL 5

NOTE: Use brake pins for guides.
RCPH10TLB417AAL 6
7. Use the three shouldered bolts and washers to pull

the brake piston and cylinder into the hub.
RCPH10TLB339AAL 7
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8. Place the brake adjuster with tapered edge facing up

into depth setting tool, part of tool kit 380002435.
RCPH10TLB407AAL 8

tool kit 380002435.
RCPH10TLB408AAL 9

NOTE: For ease of installation, look at the inside of the
adjuster ring, place tapered end down.
RCPH10TLB409AAL 10
RCPH10TLB410AAL 11
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RCPH10TLB411AAL 12
RCPH10TLB412AAL 13
kit 380002435.
RCPH10TLB413AAL 14
RCPH10TLB414AAL 15
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RCPH10TLB403AAL 16
17. Make sure the tips of the snap ring face the adjuster
RCPH10TLB490AAL 17
RCPH10TLB314AAL 18
19. Make sure the snap ring fully engages the grove in
the brake piston.
RCPH10TLB338AAL 19
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20. Place spring washers onto shouldered bolt facing as

shown.
RCPH10TLB400AAL 20

RCPH10TLB402AAL 21
22. Torque shouldered bolts to 16 N·m (141.6 lb in).
RCPH10TLB313AAL 22
23. Put the half shaft and brake separator plate pins into
the axle housing.
RCPH10TLB473AAL 23
47365539 08/07/2012
33.202 / 27

place the inner brake separator plate into the axle
housing.
NOTE: The thinner of the two separator plates is used here.
NOTICE: If using new brake disks they must be soaked in
oil for 24 hours prior to installation.
RCPH10TLB474AAL 24
25. Place the inner brake disk onto the half shaft, do not
NOTE: For the 580N there is only one brake disk, for all
SN models there are two brake disks.
RCPH10TLB475AAL 25

RCPH10TLB476AAL 26
27. Place the outer brake disk onto the half shaft, do not
RCPH10TLB477AAL 27
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33.202 / 28
28. Make sure the slots of the inner and outer brake disks
RCPH10TLB471AAL 28
RCPH10TLB472AAL 29

onto dowel rods.
NOTE: Care needs to be taken that the self adjusters are
not damaged by falling plates or by hitting them on the
housing when bringing hub into position.
RCPH10TLB478AAL 30
31. Use a piece of rope and lift the axle shaft into the
planetary gears while pushing the hub onto the axle.
NOTE: The input shaft for the differential may need to be
turned in order to align the splines on the half shaft sun
gear and the planetary gears.
RCPH10TLB479AAL 31
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33.202 / 29
32. Use LOCTITE® 270 on thread of the bolts and torque

to 226 N·m (166.7 lb ft).
RCPH10TLB383AAL 32
33. Install and tighten drain plugs and torque to 60 N·m

(44.3 lb ft).
34. Fill the axle with oil, see section 1002 for quantity and
type.
35. Connect the brake hose to the wheel cylinder, install
and tighten the hose guard mounting bolts.
RCPH10TLB066AAL 33
36. Bleed the brake according to instructions in this sec-

tion.
37. Install the wheel, do an initial torque of 136 N·m
(100.3 lb ft) in sequence shown, do a second torque
of 271 N·m (199.9 lb ft) in sequence shown, turn the
lug nuts an additional 30°.
RCPH10TLB306AAL 34
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Brakes - Test
Vehicle Brakes
NOTE: Check brake pedal free travel before proceeding.

See Brake master cylinder - Adjust - Brake pedal height
adjustment (33.202) section. Check the brake system for
leaks or damaged lines. Repair or replace as necessary.
1. Place the backhoe in the travel lock position, use the
stabilizers and raise the rear wheels off of the floor.
pin.
3. Place the range selector in 2nd gear, release the
parking brake and place the FNR selector in F or R
position.
NOTE: Make sure the differential lock is not engaged.
4. Slowly apply the brakes, both tires should stop rotat-
ing at the same time.
5. Move the machine to a clear level area with sufficient
space to accelerate the machine to 5 km/h (3 mph).
6. Once the machine has reached 5 km/h (3 mph),
quickly apply the brakes, both tires should lock and
slide.
7. Accelerate the machine to 5 km/h (3 mph).
8. Slowly apply the brakes, there should be no chat-
tering, growling, or squealing sound from the brake
system.
9. Unlock the brake pedal locking pin.
10. Accelerate the machine to 1 km/h (0.6 mph), quickly
apply the right brake, the right tire should lock and the
machine should pull to the right.
NOTE: Repeat the step for the left brake.
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Brakes - Check
NOTE: Check brake pedal free travel before proceeding.
1. Place the backhoe n the travel lock position, use the
stabilizers and raise the rear wheels off the floor.
2. Place stands under the machine, lower the machine
onto the stands making sure the wheels remain off
of the floor.
3. Attach a hose to the right bleeder valve, place the
other end in a clear container.
4. Have an assistant press the left brake pedal. Open
the bleeder valve for one minute and take measure-
ment of hydraulic fluid from the system.
5. Attach a hose to the left bleeder valve, place the
other end in a clear container.
6. Have an assistant press the right brake pedal. Open
the bleeder valve for one minute and take a measure-
ment of hydraulic fluid from the system.
NOTE: If measurements are not equal there is a restriction on the side with the lesser amount of fluid. Check lines
from axle to master cylinder and from brake reservoir to master cylinder. If no oil was present, check the feed line to
the reservoir from the oil filter.
7. Stop the engine.
8. Disconnect the brake lines from the axle, cap the
fittings on the axle, attach pressure gauges capable
of reading pressure of 3500 kPa (500 psi) to both
hoses.
pin.
10. Have another person apply the brakes and observe
the pressure readings, the pressure readings should
be the same on both gauges.
NOTE: If pressure readings are not equal, replace the mas-
ter cylinder with the lower reading,.
11. Hold the pedals in place for one minute, the pressure
should stay the same on both gauges.
NOTE: If one of the pressure readings begins to drop replace that master cylinder,.
12. Remove the gauges from the hoses, plug the hoses.
13. Remove one of the caps from the axle and con-
nect a hand pump and gauge to the brake section.
Loosen the air bleeder screw and pump the hand
pump until oil with no air flows from the air bleeder
screw. Tighten the air bleeder screw to 12 Nm (108
pound-inches). Apply 10 342 kPa (1500 psi) pres-
sure to the brake and turn off the valve on the hand
pump.
14. Observe the pressure reading for one minute, the
pressure should not drop.
NOTE: If pressure drops the brake piston seal is leaking and needs to be replaced.
NOTE: Repeat the procedure for the other side of the axle.
15. Connect the hoses to the axle and bleed the brakes.
16. Adjust the parking brake.
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Brake master cylinder - Remove

1. Park the machine on a level surface. Raise the
loader and lock the support strut to hold the loader.
2. Open the hood.
3. Disconnect the electrical connectors for the air re-
striction switch.
4. Loosen the clamp on the air cleaner hose. Discon-
nect the hose from the turbo. Put a shop cloth in the
turbo opening.
RCPH10TLB024AAL 1
5. Remove the bolts and flat washers that fasten the

fixed hood to the uprights. Remove the fixed hood
and air cleaner as an assembly.
RCPH10TLB023AAL 2
6. Push the wires for the air restriction switch through

the hole in the curtain. Remove the bolts, flat wash-
ers, and insulator curtain that covers the master
cylinders.
RCPH10TLB240ABL 3
7. Remove any dirt from the master cylinder and the

area around the master cylinder.
47365539 08/07/2012
33.202 / 33
8. Disconnect the supply and return hoses from the

master cylinder. Put caps on the fittings and plugs
in the hoses.
RCPH10TLB593AAL 4
NOTE: Supply hose and fitting are located behind the return elbow.
9. Disconnect the tubes from the master cylinder. Put
caps on the fittings and plugs in the tubes.
RCPH10TLB593AAL 5
10. Remove the cotter pins and clevis pins. Loosen and
remove the nuts that fasten the master cylinder to the
frame.
RCPH10TLB592AAL 6
11. Remove the master cylinder from the frame.
Next operation:
Brake master cylinder - Install (33.202)
47365539 08/07/2012
33.202 / 34
Brake master cylinder - Install

Prior operation:
Brake master cylinder - Remove (33.202)
1. Hold the master cylinder in alignment with the holes

in the frame and install the nuts that fasten the master
cylinder to the frame.
2. Connect the tubes to the master cylinder.
RCPH10TLB593AAL 1
3. Connect the supply line (1) from the transmission to

the supply fitting (2) on the master cylinder, connect
the return line (3) to the return fitting (4).
RCPH10TLB167ABL 2
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33.202 / 35
4. Put the clevis on the master cylinder in position on

the brake pedal. Install the clevis pin that fastens the
clevis to the brake pedal. Install the cotter pin in the
clevis pin.
RCPH10TLB592AAL 3
5. Adjust the push rods in order to achieve 1 - 3 mm

(0.039 - 0.118 in)1 to 3 MM (0.039 to 0.118 inches)
of free play measured at the pedal pad.
6. See Brakes - Remove (33.202) and remove the air
from the brake system.
7. Check for leakage at the master cylinder.
the hole in the curtain. Put the insulator curtain into
position and install the washers and bolts.
RCPH10TLB240ABL 4
9. Put the fixed hood and air cleaner assembly in posi-

tion on the uprights. Install the bolts and flat washers
that fasten the fixed hood to the uprights.
RCPH10TLB023AAL 5
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33.202 / 36
10. Remove the shop cloth from the turbo. Connect the
air cleaner hose to the turbo. Tighten the clamp on
the air cleaner hose.
RCPH10TLB024AAL 6
11. Connect the electrical connector for the air restriction

switch.
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Brake master cylinder - Adjust - Brake pedal height adjustment

1. Using the adjustment bolts, adjust the LH and RH
pedals to 90 - 92 mm (3.54 - 3.62 in).
2. Adjust the master cylinder push rods in order to
achieve 1 - 3 mm (0.039 - 0.118 in) of free play
measured at the pedal pad.
RCPH10TLB591AAL 1
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33.202 / 38
Index

Brake master cylinder - Adjust - Brake pedal height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Brake master cylinder - Exploded view - Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Brake master cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Brake master cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Brakes - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Brakes - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Brakes - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brakes - Exploded view - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brakes - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Brakes - Remove - Removing air from the brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brakes - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic service brakes - Adjust - Brake pedal height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hydraulic service brakes - Exploded view - Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic service brakes - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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PRINTED IN U.S.A.
47365539 08/07/2012
EN
SERVICE MANUAL
Hydraulic systems
580N
580SN WT
580SN
590SN
47365539 08/07/2012
35
Contents
Hydraulic systems - 35
Hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.000

580N , 580SN WT , 580SN , 590SN
Pump control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.102

580N , 580SN WT , 580SN , 590SN
Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.106

580N , 580SN WT , 580SN , 590SN
Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.204

580N , 580SN WT , 580SN , 590SN
Reservoir, cooler, and filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.300

580N , 580SN WT , 580SN , 590SN
Safety and main relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.350

580N , 580SN WT , 580SN , 590SN
Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.359

580N , 580SN WT , 580SN , 590SN
Auxiliary hydraulic valves and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.525

580N , 580SN WT , 580SN , 590SN
Stabilizer hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.703

580N , 580SN WT , 580SN , 590SN
Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.723

580N , 580SN WT , 580SN , 590SN
Excavator and backhoe hydraulic controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.726

580N NA, 580SN WT NA, 580SN NA, 590SN NA
Boom hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.736

580N , 580SN WT , 580SN , 590SN
Dipper hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.737

580N , 580SN WT , 580SN , 590SN
Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.738

580N , 580SN WT , 580SN , 590SN
47365539 08/07/2012
35
Swing arm hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.739
580N , 580SN WT , 580SN , 590SN
Telescopic arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.740

580N , 580SN WT , 580SN , 590SN
47365539 08/07/2012
35
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 262 Remote control valve - Check - Pilot control unit 35.204 / 32
Loctite® 243 Stabilizer cylinder - Torque - Stabilizer cylinder 35.703 / 4
Loctite® 243 Boom cylinder - Torque - Boom cylinder 35.736 / 4
Loctite® 243 Boom cylinder - Assemble - Boom cylinder 35.736 / 12
Loctite® 243 Dipper cylinder - Torque - Dipper cylinder 35.737 / 4
Loctite® 243 Dipper cylinder - Assemble - Dipper cylinder 35.737 / 13
Loctite® 243 Bucket cylinder - Torque - Arm tool attachment cylinder 35.738 / 4
Loctite® 243 Swing cylinder - Torque - Swing cylinder 35.739 / 4
Loctite® 243 Swing cylinder - Assemble - Swing cylinders 35.739 / 15
Loctite® 243 Telescopic arm cylinder - Torque - Extendable dipper cylinder 35.740 / 4
47365539 08/07/2012
35
580N
580SN WT
580SN
590SN
47365539 08/07/2012
35.000 / 1
Contents
TECHNICAL DATA
Hydraulic systems
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Hydraulic systems
Dynamic description - Hydraulic system identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dynamic description - Closed center hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Dynamic description - Open center hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Exploded view - Hydraulic gear pump, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Exploded view Hydraulic Pump 580SN, 580SN WT and 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Exploded view - Hydraulic gear pump seal, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hydraulic schema Regulated manifold hydraulic schematic, Pilot Controls Only . . . . . . . . . . . . . . . . . . . 46
Exploded view - Regulated manifold, Pilot Controls only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Exploded view 580N Pilot Machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Exploded view 580SN, 580SN WT and 590SN machines with pilot controls . . . . . . . . . . . . . . . . . . . . . . . 49
SERVICE
Hydraulic systems
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disassemble - Regulated manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Assemble - Regulated manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Prepare - Machine Preparation, 580N Pilot machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Test Pressure Test, 580N Pilot machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Check - Flowmeter Check Sheet, 580N Pilot machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Prepare - Machine Preparation, 580N Mechanically Controlled machines . . . . . . . . . . . . . . . . . . . . . . . . . 75
Test Pressure Test, 580N Mechanically Controlled machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Check - Flowmeter Check Sheet, 580N Mechanically Controlled machines . . . . . . . . . . . . . . . . . . . . . . . 83
Prepare Machine Preparation, All 580SN, 580SN WT and 590SN machines . . . . . . . . . . . . . . . . . . . . . . 86
Test Pressure Test, All 580SN, 580SN WT and 590SN machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Check Flowmeter Check Sheet, All 580SN, 580SN WT and 590SN machines . . . . . . . . . . . . . . . . . . . . . 99
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35.000 / 2
Adjust Torque Control Adjustment, 580SN, 580SN WT and 590SN machines with Mechanical Controls
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Adjust Torque Control Adjustment, 580SN, 580SN WT and 590SN machines with Pilot Controls . . . . 106
DIAGNOSTIC
Hydraulic systems
Testing - Problem in a loader circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Testing - Problem in the 4x1 Clam Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Testing 580N Machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Testing - Single function will not work independently from other functions . . . . . . . . . . . . . . . . . . . . . . . . 112
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Testing - Noise from the backhoe hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Testing - All pilot controls stop working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Testing - Pilot pattern change does not function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Testing - Fault codes for pilot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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Hydraulic systems - Hydraulic systems
Hydraulic systems - Special tools
RCPH10TLB080AAM 1
DATAR
CAS10090 2
CAS-10090 Hand Pump
3
CAS-10899 Charging Kit
Hydraulic systems - General specification

580N Single Gear Pump
Make and Model Parker P330 Single Section Gear Pump
Nominal Capacity of Hydraulic 115 l/min (30.5 US gpm)
Pump 580N @ 2200 RPM 108 l/min @ 231 bar ( 28.5 US gpm @ 3350 psi)
Steering Relief Pressure 162±10/-0 bar (2349.0±50 psi)
Pressure Settings
Main Relief Valve 231 bar (3350 psi) ± 3.5 bar (50 psi)
Accumulator for ride control 25 bar (362.5 psi) ± 1 bar (14.5 psi)
(Nitrogen charge)
Circuit relief valves (Hand pump setting only)
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580N Single Gear Pump

Backhoe bucket A (upper) port 296 bar (4293 psi) ± 3 bar (43.5 psi)
Backhoe bucket B (lower) port 283 bar (4105 psi) ± 3 bar (43.5 psi)
Swing A (upper) and B (lower) ports 207 bar (3000 psi) ± 3 bar (43.5 psi)
Loader bucket A (upper) and B 221 bar (3205 psi) ± 3 bar (43.5 psi)
(lower) ports
Boom A (upper) port with 221 bar (3205 psi) ± 3 bar (43.5 psi)
Mechanical Controls
Boom A (upper) port with Pilot 230 bar (3335 psi) ± 3 bar (43.5 psi)
Controls
Boom B (lower) port with Mechanical 340 bar (4930 psi) ± 3 bar (43.5 psi)
Controls
Boom B (lower) port with Pilot 360 bar (5220 psi) ± 3 bar (43.5 psi)
Controls
Dipper A (upper) port 283 bar (4103 psi) ± 3 bar (43.5 psi)
Dipper B (lower) port 250 bar (3625 psi) ± 3 bar (43.5 psi)
580SN Without Power Lift

Make and Model Bosch Rexroth Series 31 Variable Displacement Axial Piston Pump
Pump Controls Without Power Lift Option: High Pressure Cut-off (HPCO) control in pump
set to 238±3.5 bar (3450 ±50 psi)
Nominal Capacity @ 2200 RPM No Load: 156 l/min (41 US gpm)
Loader: 156 l/min @ 161 bar ( 41 US gpm @ 2335 psi)
103 l/min @ 238 bar ( 27 US gpm @ 3450 psi)
Backhoe: 156 l/min @ 214 bar ( 41 US gpm @ 3100 psi)
Pump Settings HPCO: 238±3.5 bar (3450±50 psi)
Steering relief pressure 162±10/-0 bar (2349.0±150-0 psi)
Standard Main Relief Pressure 238±3.5 bar (3450±50 psi)
Heavy Lift Main Relief Pressure 250±3.5 bar (3625.0±50 psi)
(lower) ports
Mechanical Controls
Controls
Controls
Controls
Swing Relief Pressure 207+7/3 bar (3001.5+100/-50 psi)at 53 l/min (14.0 US gpm)
580SN With Optional Power Lift

Make & Model Bosch Rexroth Series 31 Variable Displacement Axial Piston Pump
Pump Controls 1. LS Control with remote LS Relief Valve.
2. Primary remote LS relief in Power Lift valve for main relief pressure.
3. Secondary remote LS relief in Power Lift for "Power Lift" pressure
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580SN With Optional Power Lift

Power Lift capacity No load: 99.3 l/min (26.2 US gpm).
Max. Heavy lift capacity: 55 l/min (14.5 US gpm) 250 bar (3625.0 psi)@
1400 RPM.
(lower) ports
Mechanical Controls
Controls
Controls
Controls
580SN WT With Standard Power Lift

Power Lift capacity @ 1400 RPM No load: 99.3 l/min (26.2 US gpm).
Max. Power Lift capacity: 55 l/min (14.5 US gpm) 261 bar (3780 psi)@
1400 RPM.
(lower) ports
Mechanical Controls
Controls
Controls
Controls
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590SN With Standard Power Lift

Nominal capacity No Load: 162.6 l/min (43 US gpm)
Loader: 162.6 l/min @ 161 bar ( 43 US gpm @ 2335 psi)
107.8 l/min @ 238 bar ( 28.4 US gpm @ 3450 psi)
Backhoe: 162.6 l/min @ 214 bar ( 43 US gpm @ 3100 psi)
Power Lift capacity No load: 107 l/min (28.3 US gpm).
Max. Heavy lift capacity: 66 l/min (17.4 US gpm) 250 bar (3625.0 psi)@
1400 RPM.
(lower) ports
Mechanical Controls
Controls
Controls
Controls
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Hydraulic systems - Dynamic description - Hydraulic system

identification
N series loader backhoe hydraulic system identification
Depending on model, the N Series Loader Backhoes can be equipped with numerous different hydraulic control sys-
tems. To be able to correctly diagnose hydraulic system problems a technician must be able to determine how the
particular machine is equipped. This information will allow a tech to visually identify the installed hydraulic system to
determine which hydraulic schematic is correct.
There are two different hydraulic valve systems on the N Series Loader Backhoes. A single section gear pump sup-
plies the oil on 580N models. Variable displacement piston pumps supply the oil on all of the 580SN and 590SN
models.
All of the models have mechanically controlled loader valves. The design and manufacturer of the loader valves varies
depending on model and type of backhoe control valve installed.
All of the models have mechanically controlled backhoe control valves as standard equipment. Hydraulically actuated
pilot operated backhoe controls are available as an option on all models.
There are five variations of hydraulic schematics published for the N Series Loader Backhoes. These variations are:
• 580N with Mechanical Backhoe Controls
• 580N with Pilot Backhoe Controls
• 580SN, 580SN-WT and 590SN With Mechanical Backhoe Controls Without PowerLift
• 580SN, 580SN-WT and 590SN With Mechanical Backhoe Controls With PowerLift
• 580SN, 580SN-WT and 590SN With Pilot Backhoe Controls With PowerLift
The best way to determine which schematic is required to service the machine is to determine which backhoe controls
are installed.
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Depending on model, there are numerous hydraulic system variations and options available for the N Series loader
backhoes. Due to these variations, effective troubleshooting requires identification of how the machine is equipped.
This chart lists the standard and optional variations that may be found.
580N 580N 580SN 580SN 580SN 580SN 590SN 590SN

Mech Pilot Mech Pilot WT WT Mech Pilot
Ctrl Ctrl Ctrl Ctrl Mech Pilot Ctrl Ctrl
Mechanical Backhoe Std Std Std Std
Controls
Pilot Backhoe Opt Opt Opt Opt
Controls
Gear Pump Std Std Not Not Not Not Not Not
Avail Avail Avail Avail Avail Avail
Rexroth 71 CC Not Not Std Std Std Std Not Not
Variable Piston Avail Avail Avail Avail
Pump
Rexroth 74 CC Not Not Not Not Not Not Std Std
Variable Piston Avail Avail Avail Avail Avail Avail
Pump
Husco (black) open Std Std Std Std Std
center loader valve
Rexroth (blue) Opt Opt Opt
closed center loader
valve
Hydraulic Cold Start Not Not Opt Not Opt Not Opt Not
Avail Avail Avail Avail Avail
PowerLift Not Not Opt Not Std Std Std Std
Avail Avail Avail
Husco (black) open Std Std Std Std
center backhoe
valve
Rexroth (blue) Opt
closed center with
open center inlet
compensator
closed center with
minimum flushing
valve
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The best way to determine which schematic is required to service the machine is to determine which backhoe controls
are installed. Following are descriptions of each of these systems:
Mechanical Backhoe controls Identification.

Mechanical backhoe controls consist of lever rods with knobs at the top. These control levers and pedals are located
between the legs of the operator. Mechanical backhoe controls come in two different versions.
Mechanical backhoe control with foot swing and extend-a-hoe

The graph below shows the mechanical backhoe controls with foot controlled swing. The standard version is foot
swing.
RAPH12TLB0112BA 1
Mechanical backhoe-foot swing
1. Left Swing 3. Bucket 5. Boom 7. Extendable Dipper –

Extendahoe
2. Stabilizers 4. Dipper 6. Right Swing
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Mechanical backhoe with hand control swing

The graph below shows the mechanical backhoe controls with hand controlled swing. The optional version on me-
chanical backhoe control is hand swing.
RAPH12TLB0113GA 2
Mechanical backhoe with hand control swing
1. Boom and Swing 4. Bucket and Dipper

2. Left Stabilizer 5. Extendable Dipper - Extendahoe
3. Right Stabilizer
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Pilot backhoe controls identification

Hydraulic pilot backhoe controls are available as an option on all of the N Series Models. The design of the pilot
backhoe control valve is between the 580 N series models and the 580SN and 590SN model. The design is different
because of the different types of hydraulic pumps. The 580N model is equipped with a gear pump. All of the SN
models are equipped with variable displacement piston pumps
To identify if the machine is equipped with pilot backhoe controls, check the design and location of the backhoe control
levers. Pilot backhoe controls consist of two control towers, that include hydraulic joystick control valves. Below are
graphics showing pilot backhoe controls. All pilot backhoe controlled units are equipped with a control pattern change
feature. The boom and dipper control pattern can be changed by activating a control switch on the right backhoe
control tower. Pilot backhoe control pattern #1 – Pattern change switch light OFF
RAPH12TLB0114EA 3
Backhoe control pattern #1 — Pattern change switch light OFF
1. Boom and Swing 2. Dipper and Bucket
RAPH12TLB0115EA 4
Pilot backhoe control pattern #2 — Pattern change switch light ON
1. Dipper and Swing 2. Boom and Bucket
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PowerLift feature
All 580SN and 590SN models equipped with a pilot operated backhoe valve are equipped with the PowerLift feature.
The PowerLift feature is also optional on 580SN units equipped with mechanical controls. This feature is not available
as an option on the 580N units as they are equipped with a gear pump, which is incompatible with this feature. The
PowerLift feature increases the backhoe hydraulic system operating pressure to allow for lifting heavier items such
as septic tanks under limited conditions.
This feature is controlled by a two position rocker switch located on the right hand control panel near the hand throttle
and a seat position switch. In addition to increasing the backhoe system operating pressure, the PowerLift system
reduces the engine speed to approximately 1450 RPM. The rocker switch is momentary and springs back to center
when released. Press the emblem end of the rocker switch to activate PowerLift. The PowerLift image appears in the
AIC display screen. Press the emblem end again to turn off PowerLift. If PowerLift will not engage, a slash appears
through the image in the display screen and an audible alarm sounds. Ensure that the engine is warm, the direction
control lever is in neutral, and the operator’s seat is locked in the backhoe operation position. If it still does not engage,
troubleshoot the electronic throttle system.
RAPH12TLB0116EA 5
Location of the PowerLift switch
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Hydraulic systems - Dynamic description - Closed center hydraulic

system
580SN and 590SN Pilot Backhoe Controls – Closed Center Piston Pump Hydraulic System
Depending on model, there are numerous hydraulic system variations and options available for the N Series Loader
Backhoes. Effective troubleshooting requires identification of how the machine is equipped. This chart lists the stan-
dard and optional variations that may be found. For detailed information on identifying the system, see Hydraulic
systems - Dynamic description (35.000) .
580N 580N 580SN 580SN 580SN 580SN 590SN 590SN

Mechanical Std Std Std Std
BackHoe Controls
Controls
Pump
Pump
center loader valve
valve
PowerLift Not Not Opt Std Std Std Std Std
Avail Avail
center backhoe
valve
Rexroth (blue) Opt
closed center with
open center inlet
compensator
closed center with
minimum flushing
valve
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The SN Series of loader backhoes can be equipped with a hydraulic pilot operated backhoe control valve as optional
equipment. The hydraulic systems on these units are of the closed center design. In a closed center hydraulic system,
oil does not flow through the hydraulic control spools when they are not activated and are in neutral. On this closed
center system with the spools in neutral, the pump only delivers the flow required to maintain an output pressure of
approximately 20 bar (290 psi). On the SN models equipped with a pilot operated backhoe valve (20), the loader
valve (4) is also of a closed center design.
With the pilot backhoe valve (20) system, the hydraulic pump (40) is of variable displacement pressure and flow
compensated (PFC) load sense design. It is mounted to the rear of the transmission, under the cab. All SN models
equipped with a pilot operated backhoe valve are equipped with the PowerLift (48) feature. The PowerLift feature
increases the backhoe system pressure to allow for lifting heavier items such as septic tanks under limited conditions.
This feature is controlled by a two position rocker switch located on the instrument control panel and a seat position
switch. In addition to increasing the backhoe system operating pressure, the PowerLift system reduces the engine
speed to approximately 1450 RPM. This reduced engine speed increases the operational precision when handling
heavier objects.
Pump outlet flow is available to the inlet of the loader valve (4). The loader valve is located under the right front of the
cab. The loader lift and bucket circuits are mechanically controlled by a single lever on the right console. A priority
flow divider is also located in the loader valve inlet section to first send oil to the steering system. When steering is
satisfied, the priority spool would then send oil to the loader circuits.
Auxiliary backhoe hydraulics are an option. Two versions are available, uni-directional (14) and combo. Full pump flow
is also available to the uni-directional auxiliary hydraulic valve (14). The bi-directional feature of the combo auxiliary
system is controlled by a spool in the pilot backhoe valve. Both of the auxiliary hydraulic systems utilize the same
plumbing lines on the backhoe.
In SN units equipped with the pilot operated backhoe valve, the boom, bucket, dipper and swing circuits are controlled
by two hydraulic pilot joystick valves. Swing is controlled by side to side movement of the left lever. The bucket circuit
is controlled by side to side movement of the right lever. The boom and dipper circuits are controlled by the fore and
aft movement of the levers. The control pattern can be changed by a switch located on the right control tower. With
the switch in position 1, power OFF, the right lever controls dipper and the left lever controls the boom. With the switch
in position 2, power ON, the right lever controls the boom and the left lever controls the dipper.
2. Steering control valve 39. Pump pressure test port and attenuator hose
4. Loader valve 40. Hydraulic pump
7. Clam pilot control 43. Reservoir
14. Uni-directional auxiliary valve (optional) 44. Oil cooler
17. Backhoe pilot control manifold 45. Oil filter
20. Pilot backhoe control valve 48. PowerLift control valve
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RAPH12TLB0119FA 1
580SN Pilot backhoe control valve
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Pump
All of the SN series loader backhoes are equipped with variable volume piston pumps (40). On units equipped with
the Pilot operated backhoe control valve (20), the variable volume pump is of pressure and flow compensated (PFC)
design and requires a load sense (LS) signal to deliver oil. This pump only delivers the flow required to satisfy the
operator demand. The more that a control spool or spools are activated, the more flow that the pump will deliver.
Once the maximum pressure is reached, the flow reduces to only the amount required to maintain the pressure.
The engine horsepower required to drive the pump (40), depends on the flow delivered by the pump in lpm (GPM),
as well as the pressure, Bar (psi) at which the system is operating. There is a mathematical formula to calculate the
horsepower needed to drive a pump. It requires approximately 0.7 kW (1 Hp) to deliver 1 US gpm of oil at about 103
bar (1500 psi). Therefore, it would require approximately 18 kW (25 Hp) to deliver 95 l/min (25 US gpm) at 103 bar
(1500 psi). If the pressure doubles to 207 bar (3000 psi), the horsepower requirement would double to about 37 kW
(50 Hp).
• 1 US gpm at approximately 103 bar (1500 psi) requires approximately 1 kW (1 Hp)

• 95 l/min (25 US gpm) at approximately 103 bar (1500 psi) requires approximately 18 kW (25 Hp).
• 95 l/min (25 US gpm) at approximately 207 bar (3000 psi) requires approximately 37 kW (50 Hp).
The transmission is used while using the loader. A portion of the available engine horsepower is required to move
the unit while using the loader. Because of this, full engine power is not available for the hydraulic system. For this
reason, only one section of the gear pump is used while operating the loader on models prior to the 580SN Series.
While operating the backhoe, full engine power is available to the hydraulic system as the vehicle is stationary. On
earlier loader backhoe models, both of the hydraulic gear pump sections are combined to supply oil to the backhoe
functions.
The SN Series loader backhoes use a single section variable piston pump (40). This pump is capable of delivering full
flow under all conditions. Because the transmission requires power to move the machine, the piston pump requires
a torque control system to limit the hydraulic flow while operating the loader. With the torque control system active
and the seat in the forward position, the pump will deliver full flow until the outlet pressure reaches approximately 152
bar (2200 psi). The torque control solenoid (40F) is active when the seat is in the forward direction. If the engine
lugs down excessively while operating the loader, the torque control solenoid (40F) may be defective. If the backhoe
operates slower than expected, the torque control solenoid could be the cause.
Pilot backhoe control valve legend

2. Steering control valve 38. Quick coupler solenoid valve
3. Comfort steering control valve 39. Pump pressure test port and attenuator hose
7. Clam pilot control 40A. Torque control compensator stool
14. Uni-directional auxiliary valve (optional) 40B. High pressure cut off spool
17. Pilot regulated manifold 40C. Pumping element
20. Pilot backhoe control valve 40D. Destroke piston
20A. Minimum flow bypass valve 40E. Onstroke piston
20B. Pressure spike reducer 40F. Torque control solenoid
20D. Swing spool 40G. Larger torque control orifice
20G. Boom spool 40H. Smaller torque control orifice
20K. Left stabilizer spool 40J. LS signal leak down orifice
20L. Right stabilizer spool 40K. Variable torque pressure regulator
20M. Dipper spool 43. Reservoir
20P. Bucket spool 44. Oil cooler
20S. Extendahoe spool 45. Hydraulic filter
20U. Bi-directional auxiliary spool 46. Dual auxiliary return valve
35. 5 Bar back pressure valve 48. PowerLift control valve
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RAPH12TLB0120GA 2
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Pressure control
On the 580SN machines without the PowerLift option, maximum system pressure is controlled by the high pressure
cutoff spool in the compensator on the hydraulic pump. When the maximum system pressure is reached, this control
spool reduces the pump flow to only as much as is required to maintain this pressure. Due to the reduction in pump
flow at full pressure, the horsepower load reduces at full pressure.
The PowerLift (48) feature is optional on the 580SN machines equipped with mechanical backhoe controls. The
PowerLift feature is standard equipment on the 580SN WT and 590SN machines equipped with mechanical controls.
PowerLift is also standard on all SN models equipped with pilot backhoe controls. PowerLift is not available on 580N
machines.
The PowerLift (48) feature increases the backhoe system pressure to allow for lifting heavier items such as septic
tanks under limited conditions. This feature is controlled by a two position rocker switch located on the instrument con-
trol panel and a seat position switch. In addition to increasing the backhoe system operating pressure, the PowerLift
system reduces the engine speed to approximately 1450 RPM. This reduced engine speed increases the operating
precision when handling the heavier objects. The PowerLift system can only be activated with the seat facing the
backhoe operating position.
The PowerLift valve is located near the hydraulic Reservoir under the cab. Adjust the RV1 Normal pressure relief
valve (1) to control the normal system operating pressure. Adjust the RV2 PowerLift pressure relief valve (2) while
operating the backhoe with the PowerLift switch activated. The engine operates about 1450 RPM when the system
is active.
RAPH12TLB0124EA 3
Mechanical and Pilot PowerLift valves
1. RV1 Normal pressure relief 4. LS Drain orifice

2. RV2 PowerLift pressure relief 5. LS Input pressure from valve
3. PowerLift solenoid 6. Solenoid connector
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Attenuator
To reduce hydraulic noise in the system a specific length and size attenuator hose (39) is connected to a tee fitting at
the outlet of the pump. The blank hose is routed towards the rear of the machine. The system pressure test port at the
end of the attenuator is secured under the right rear of the machine, near the backhoe control valve. If replacement
is required, us the exact hose specified.
Pilot backhoe control equipped loader valve — closed center

On 580SN and 590SN Loader Backhoes equipped with the pilot backhoe valve control system, all of the circuits are
of closed center design in which no oil will flow through them in the neutral position. The output of the pump is directly
connected to the loader and backhoe valves and also to the uni-directional auxiliary valve if the unit is equipped with
that option. The steering and optional coupler control valve circuits are supplied from the priority valve located in the
loader valve inlet section.
RAPH12TLB0065AA 4
Pilot system loader valve
1. Clam spool 6. Priority flow to steering

2. Bucket spool 7. Priority spool
3. Lift spool 8. Inlet
4. LS port 9. DLS port not visible next to priority spool
5. Outlet
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The loader valve (4) is a closed center type of valve. This valve has a priority valve (H) located in the inlet section
to provide oil to the steering and bucket coupler circuits. The maximum operating pressure in all of the loader and
backhoe circuits is controlled by the relief valves located in the PowerLift valve (48). This multi-section loader valve
is available with either two or three spools, depending on whether the unit has the optional loader auxiliary/clam
hydraulics installed. The loader lift (G) and bucket (E) spools are manually actuated. The optional auxiliary/clam
spool (A) is electro-hydraulic pilot controlled by the clam control valve (7). The solenoids that control the clam circuit
are of proportional design in that they control the flow from the circuit in direct relation to the amount that the control
switch is activated. The switch that controls the clam circuit is a thumb actuated potentiometer located in the loader
control lever handle.
The loader valve has a priority valve (H) located in the inlet section to provide oil to the steering and bucket coupler
circuits. This multi-section loader valve is available with either two or three spools, depending on whether the unit has
the optional loader auxiliary/clam hydraulics installed. The loader lift (G) and bucket (E) spools are manually actuated.
The optional auxiliary/clam spool (A) is electro-hydraulic pilot controlled by the clam control valve.
Pilot loader valve schematic legend

A. Clam spool G. Lift spool
B. Sectional compensator H. Priority valve
C. Load check valve J. Dynamic load sense orifice
D. Circuit relief valve K. Steering load sense check valve
E. Bucket spool L. Orifice/Check valve
F. Anti-Cavitation check valve
Pilot backhoe control valve schematic legend

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RAPH12TLB0043EA 5
RAPH12TLB0120GA 6
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All of the loader spools have equal access to pump supply flow. This allows all of the circuits to operate at the same
time, depending on the pressure and flow requirements. The bucket section (E) has two-circuit relief valves (D) to
protect that circuit when the spools are in neutral. The Loader lift spool (G) has float capability. When in the float
position both ends of the cylinder are connected to the tank so the loader which can follow the contour of the ground.
The loader lift circuit can be equipped with an optional ride control system to allow the loader to be cushioned when
traveling. The ride control can be turned on or off by using the switch on the right-hand console. If the ride control
switch is in the on position, there will be no loader down pressure. Automatic Ride Control engages ride control while
the vehicle is moving and turns it off while stationary. Ride Control engages automatically on 4WD units when the
switch is turned on. Ride control engages while the 4WD vehicle is moving or stationary on 2WD units when the
switch is turned on.
Each of the 580SN and 590SN pilot backhoe valve equipped loader valve circuits has a flow compensator spool (B)
to prevent unexpected flow changes when another circuit is actuated. The maximum flow available for each circuit is
limited and is controlled by spool travel and the notches on the control spool. Each of the loader circuits have a load
check (C) feature to prevent the load from dropping as the circuit is gradually activated. In the loader circuits, the load
check feature is incorporated into the compensator spool.
Pilot loader valve schematic legend

A. Clam spool G. Lift spool
B. Sectional compensator H. Priority valve
C. Load check valve J. Dynamic load sense orifice
D. Circuit relief valve K. Steering load sense check valve
E. Bucket spool L. Orifice/Check valve
F. Anti-Cavitation check valve
Pilot backhoe valve schematic legend

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RAPH12TLB0043EA 7
RAPH12TLB0120GA 8
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Steering and bucket coupler system

When the steering system is activated, priority oil will flow from the “D” port from the flow divider in the inlet section of
the loader valve (4) to the steering hand pump (2) and to the bucket coupler control valve (38) if the unit is equipped
with that option. Pump output oil not required by the steering system then flows from EF port of the priority flow divider
equally to all spools of the loader valve. The steering control is a closed center load-sensing valve mounted in the
steering column. When the steering system is actuated by the steering wheel, a load sense signal, which is equal
to the pressure required to steer the unit, is returned to the DLS port of the loader valve. This will cause the priority
valve in the inlet of the loader valve to deliver only as much oil to the steering system as required. The maximum
steering pressure is controlled by a load sense relief valve located in the steering hand pump (2). Comfort Steering
(3) is an available optional feature. When activated, comfort steer reduces the number of steering wheel rotations
required to turn fully from one direction to the other by half. This feature is beneficial when operating the loader in
close quarters. Comfort steer only functions while the transmission is in first or second gears. When the comfort steer
valve (3) is activated, supply pressure shifts the spool within the hand pump (2). Comfort steering is active in first and
second gear only. It automatically disengages when third gear is selected. The comfort steer activation switch must
be activated to engage the comfort steering system.
The flow divider oil from the “D” port in the inlet section of the loader valve is also available to the optional bucket
coupler control valve (38). The quick coupler system allows the operator to change the bucket or other attachments
from the operators seat. The relief valve in the coupler valve limits the maximum coupler circuit pressure by limiting
the load sense signal pressure returned to the priority flow divider. During normal operation, steering circuit pressure
is ported to the locking side of the coupler cylinder keeping it locked.
Pilot control backhoe valve – closed center

The 580SN and 590SN Series pilot control backhoe valve is a multi-section design with a closed center flow path.
When circuits are activated, the compensator in the pump continuously maintains a 20 bar (290 psi) differential be-
tween the pump outlet and load sense pressures. The multi-section pilot control backhoe valve is available with either
six, seven or eight spools, depending on whether the unit has Extend-A-Hoe and or bi-directional auxiliary hydraulics
installed.
On 580SN, 580SNWT, and 590SN machines equipped with pilot control backhoe, a dual function flushing (3) and
spike pressure reducing (5) valve spool is installed in the backhoe valve inlet section (1). The flushing valve (3) allows
approximately 35 l/min (9.2 US gpm) to flow through the system at low pressure when all spools are in neutral and
the Load Sense (LS) signal is vented to tank pressure. The amount of oil flushing through the valve with the backhoe
control spools in neutral is regulated by the flushing orifice (4) in the pressure spike reducer spool (5). The flushing
valve makes a slight hissing noise when open, and clicks each time it closes. These sounds are normal and are no
cause for alarm. The flushing valve allows the system to warm up better, especially in cold climates. The flushing
valve also assists filtration and cooling under normal operating conditions. If the flushing spool orifice gets plugged,
the flushing spool would not close correctly causing slow operation of all hydraulic functions.
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RAPH12TLB0121GA 9
Backhoe flushing valve cutaway
1. Pilot valve inlet section 5. Pressure spike reducing spool

2. Pressure spike reducing spring 6. Flushing spool load sense (LS) orifice
3. Flushing spool 7. Load sense (LS) pressure passage
4. Pressure spike reducing flushing orifice
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PowerLift options
On 580SN units not equipped with the PowerLift option, the maximum hydraulic system pressure is limited by the
high pressure cutoff spool in the hydraulic pump compensator. On all of the 580SN and 590SN units equipped with
the PowerLift feature, the maximum system pressure is limited by the load sense (LS) relief valves located in the
PowerLift control valve. This pressure control requires the pump to destroke to limit the maximum pressure. There is
a slight delay in response time for this flow cut-off to happen which may cause a pressure spike. To limit the pressure
spikes, there is a spike pressure reducing valve located in the inlet section of the backhoe control valve. This valve
is set at approximately 276 bar (4000 psi), which is higher than the maximum system operating pressure.
The swing, boom, dipper and bucket circuits are controlled by hydraulic pilot control joysticks. An in-cab pattern
change switch can change from backhoe to excavator control pattern with no tools required. The pattern change
switch is located at the base of the right hand backhoe control tower. The Extendahoe, bi-directional auxiliary and
both stabilizer circuits are electronically controlled via proportional solenoids. The Extend-A-Hoe circuit is actuated
by a thumb actuated proportional switches (5) and (6), located in the right backhoe control (4). The stabilizers are
fingertip switch controlled at the base of the left backhoe control tower. The bi-directional auxiliary hydraulic system
are controlled by push buttons (2) at the top of the left hand backhoe control lever (1). If the unit is equipped with the
optional uni-directional auxiliary system, a single switch at the top of the left control lever activates it. The operator
can easily toggle between the adjustment of the hand throttle control and idle by activating the engine idle button (7)
at the top of the right control lever (4).
RAPH12TLB0122EA 10
Backhoe control levers
Left Image Right Image

1. Left pilot backhoe control lever 4. Right pilot backhoe control lever
2. Auxiliary control buttons 5. Extendahoe retract button
3. Horn button 6. Extendahoe extend button
7. Engine idle button

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RAPH12TLB0120GA 11
580SN pilot backhoe control valve
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The swing (20D) and auxiliary (20U) hydraulic sections have pilot operated circuit relief valves with anti-cavitation
check valves. All of the other circuits, except stabilizer (20K) and (20L), have direct acting circuit relief valves with
anti-cavitation check valves. The boom spool also has an additional internal anti-cavitation feature built into it to
limit problems with the boom down circuit. The anti-cavitation valves allow oil from the tank circuit to enter into the
circuit when a vacuum is created as gravity causes the function to move faster than the oil flow available. The anti-
cavitation check valves also allow make-up oil to enter the circuit when the opposite circuit relief valve opens. The
swing circuit has an anti-rebound valve which slows the swing system gradually to make the system operate smoothly.
Both stabilizer sections have two-way lock check valves installed in them. These lock checks help hold the stabilizers
in either the up or down position.
Each of the backhoe circuits has a flow compensator spool to prevent unexpected flow changes when another circuit
is actuated. The maximum flow available for each pilot controlled backhoe circuit is limited and is controlled by the
spool travel and the notches on the control spool. The maximum flow available for the circuits are different in some
of the circuits to control the cylinder speeds. Each of the backhoe circuits have load check valves to prevent the load
from dropping as the circuit is gradually activated. In the boom (20G), dipper (20M), bucket (20P) and extend-a-hoe
(20S) circuits, the load check feature is incorporated into the flow compensator spool.
Auxiliary hydraulics
Hydraulically operated attachments can be used with the backhoe. Some of the attachments only require a controlled
oil source and a return, uni-directional (14). Hydraulic hammers and tampers require oil flow in one direction only and
typically require a low pressure return to the reservoir to function properly. Other attachments require pressurized oil
in two directions, bi-directional (20U). Two different auxiliary control options are available. The first auxiliary option
consists of the uni-directional oil flow with a low pressure return only. The second auxiliary option is referred to as the
combo system. The combo system consists of both the uni-directional system and the bi-directional system.
Full pump output flow is equally available to the loader valve (4), backhoe valve (20) and also the optional uni-direction
auxiliary valve (14), if equipped. The optional uni-direction auxiliary hammer valve (14) allows the operator to select
the flow required to operate a hammer or similar attachment. Electrical power to the optional hammer valve circuit is
supplied through the pilot enable switch on the right hand backhoe control tower. On units equipped with pilot backhoe
controls, the uni-direction auxiliary hydraulic system is controlled by a button switch at the top of the left hand backhoe
control lever. If equipped, the electrically controlled uni-direction valve is located above the right rear axle.
If the unit is equipped with the optional combination/dual auxiliary hydraulic system, a switch on the console near the
hand throttle enables power to the selected auxiliary hydraulic system only. Proportional control buttons at the top of
the left backhoe control lever, control auxiliary flow when the bi-directional mode has been selected.
The combo auxiliary option includes the uni-direction auxiliary system as well as a bi-directional auxiliary control spool
in the backhoe valve. The bi-directional system uses the same plumbing on the boom and the dipper. When equipped
with the combo hydraulic kit, a hydraulic pilot operated dual auxiliary return valve is connected to one of the auxiliary
lines. This dual auxiliary return valve (46) is hydraulically operated by the oil pressure from the activated uni-direction
valve (14). This valve allows the return flow to be diverted directly to the hydraulic filter when the uni-direction system
is activated.

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RAPH12TLB0120GA 12
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Hydraulic systems - Dynamic description - Open center hydraulic

system
580SN and 590SN Mechanical Backhoe Controls - Open Center Hydraulic System
Depending on model, there are numerous hydraulic system variations and options available for the N Series Loader
Backhoes. Due to these variations, effective troubleshooting requires identification of how the machine is equipped.
This chart lists the standard and optional variations that may be found.
580N 580N 580SN 580SN 580SN 580SN 590SN 590SN

Mechanical Backhoe Std Std Std Std
Controls
Controls
Pump
Pump
center loader valve
valve
PowerLift Not Not Opt Std Std Std Std Std
Avail Avail
center backhoe
valve
Rexroth (blue) Opt
closed center with
open center inlet
compensator
closed center with
minimum flushing
valve
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The SN Series of loader backhoes are equipped with a mechanically operated backhoe control valve (20) as standard
equipment. The hydraulic systems on these units are of the open center design. In an open center hydraulic system,
oil continues to flow through the hydraulic control spools when they are not activated and are in neutral. As the pump
(40) reaches the high pressure cut-off setting, the load on the engine will be less.
Pump
All of the SN series loader backhoes are equipped with variable volume piston pumps (40). On units equipped with
the mechanically operated backhoe control valve (20) , the variable volume pump delivers full flow up to the maximum
system pressure. Once the maximum pressure is reached, the flow reduces to only the amount required to maintain
the pressure.
The engine horsepower, required to drive the pump, depends on the flow delivered by the pump (GPM), as well as
the pressure (psi) at which the system is operating. There is a mathematical formula to calculate the horsepower
needed to drive a pump. It requires approximately 0.7 kW (1 Hp) to deliver 3.8 l/min (1.0 US gpm)of oil at about 103
bar (1500 psi). Therefore, it would require approximately 18 kW (25 Hp) to deliver 95 l/min (25 US gpm) at 103 bar
(1500 psi). If the pressure doubles to 207 bar (3000 psi), the horsepower requirement would double to about 50 HP
37 kW (50 Hp).
The transmission is used while using the loader. A portion of the available engine horsepower is required to move
the unit while using the loader. Because of this, full engine power is not available for the hydraulic system. This is the
reason that only one section of the gear pump is used while operating the loader on models prior to the 580N Series.
While operating the backhoe, full engine power is available to the hydraulic system as the vehicle is stationary. On
earlier loader backhoe models, both of the hydraulic gear pump sections are combined to supply oil to the backhoe
functions.
The N Series loader backhoes use a single section variable piston pump (40). This pump is capable of delivering full
flow under all conditions. Because the transmission requires power to move the machine, the piston pump requires a
torque control system to limit the hydraulic flow while operating the loader. With the torque control system active, with
the seat in the forward position, the pump will deliver full flow until the outlet pressure reaches approximately 152 bar
(2200 psi). The torque control solenoid is active when the seat is in the forward direction. If the engine lugs down
excessively while operating the loader, the torque control solenoid (40F) may be defective. If the backhoe operates
slower than expected, the torque control solenoid could be the cause.
Cold start option

With the open center mechanical backhoe control system, the pump is at full displacement during startup. To assist
starting in cold climate conditions, a cold start option (40L) is available. Only SN loader backhoe models equipped
with mechanical backhoe controls can be equipped with this option. The cold start option is included on machines that
are ordered with the glow plug and dual battery option. A solenoid controls this feature. This solenoid is energized
when the starter is engaged. The pump goes to minimum flow while this solenoid is active. If this solenoid were to
stick in the energized position, none of the hydraulic functions would work.
2. Steering Control Valve 40. Hydraulic Pump

4. Loader Valve 40A. Torque control compensator spool
7. Clam Pilot Control 40B. High pressure cut off spool
14. Uni-Directional Auxiliary Valve (Optional) 40C. Pumping element
20. Mechanical Backhoe Control Valve 40D. Destroke piston
20D. Swing Spool 40E. Onstroke Piston
20G. Boom Spool 40F. Torque Control Solenoid
20K. Left Stabilizer Spool 40G. Larger Torque Control Orifice
20L. Right Stabilizer Spool 40H. Smaller Torque Control Orifice
20M. Dipper Spool 40J. LS Signal Leak down Orifice
20P. Bucket Spool 40K. Variable Torque Pressure Regulator
20S. Extendahoe Spool 40L. Hydraulic Pump Cold Start Solenoid
20U. Bi-Directional Auxiliary Spool 44. Oil Cooler
38. Quick Coupler Solenoid Valve 45. Hydraulic Filter
39. Pump Pressure Test Port & Attenuator Hose 48. PowerLift Control Valve
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RAPH12TLB0069GA 1
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Pressure control
On the 580SN machines without the PowerLift option, maximum system pressure is controlled by the high pressure
cut-off spool (40B) in the compensator on the hydraulic pump. When the maximum system pressure is reached, this
control spool reduces the pump flow to only as much as is required to maintain this pressure. Due to the reduction in
pump flow at full pressure, the horsepower load reduces at full pressure.
The PowerLift feature is optional on the 580SN machines equipped with mechanical backhoe controls. The PowerLift
feature is standard equipment on all 580SN WT and 590SN machines. PowerLift is not available on 580N machines.
The PowerLift feature increases the backhoe system pressure to allow for lifting heavier items such as septic tanks
under limited conditions. This feature is controlled by a two position rocker located on the instrument control panel
and a seat position switch. In addition to increasing the backhoe system operating pressure, the PowerLift system
reduces the engine speed to approximately 1450RPM. This reduced engine speed increases the operating precision
when handling the heavier objects.
RAPH12TLB0124EA 2
PowerLift valve with Mechanical and Pilot backhoe valves
1. RV1 Normal Pressure Relief 4. LS Drain Orifice

2. RV2 PowerLift Pressure Relief 5. LS Input Pressure From Valve
3. PowerLift Solenoid 6. Solenoid Connector
Attenuator
To reduce hydraulic noise in the system a specific length and size attenuator hose is connected to a tee fitting at the
outlet of the pump. The blank hose is routed towards the rear of the machine. The system pressure test port at the
end of the attenuator is secured under the right rear of the machine, near the backhoe control valve. If replacement
is required, use the exact hose specified.
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Mechanical control loader valve — open center

On units equipped with a mechanically controlled backhoe valve, the Loader valve is an open center type valve. The
loader lift and bucket control spools of this valve are mechanically controlled. This valve has a priority flow divider
and a pressure spike reducing valve installed in the inlet section. The loader valve is a mono-block design, in that the
inlet, bucket and loader lift sections are a single casting. The valve is painted black. If the unit is equipped with a third
section at the factory, the mono-block will have all three spools. The third or clam spool is activated by proportional
hydraulic solenoids which are controlled by a thumb switch on the loader control handle.
RAPH12TLB0123FA 3
1. Inlet Port 6. Lift Section

2. Pressure Spike Reducer 7. Bucket Spool
3. Priority Spool (Internal Component) 8. Clam (Third) Spool
4. Steering Pressure Port 9. Power Beyond Port To Backhoe
5. LS Port 10. Outlet Port
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The remaining secondary oil from the priority valve (B) flows to the loader valve functions. All of the pump flow passes
through the priority valve (B) located in the inlet of the loader valve. The controlled flow (CF), priority outlet of the
priority valve (B) feeds the steering circuit and optional hydraulic attachment coupler valve. The maximum hydraulic
system pressure is limited by the high pressure cut-off spool in the hydraulic pump compensator. This pressure control
requires the pump to destroke to limit the pressure. There is a slight delay in response time for this flow cutoff to
happen which may cause a pressure spike. To limit the pressure spikes, there is a spike pressure reducing valve
(A) before the loader valve control spools. This valve has to be adjusted higher than the maximum system operating
pressure at approximately 4000 psi.
The bucket section (E) has two-circuit relief valves (D) installed in it to protect the maximum pressure in that circuit
with the spools in neutral. If the bucket circuit is fully stroked there will be no oil sent to the loader lift spool (G),
although there will be oil available to the clam spool (H). A mechanical linkage system levels the bucket spool as the
loader is raised. When the loader height is above about 46 cm (18 in), the bucket spool cannot be fully actuated. The
Loader lift spool has a float capability. When the loader lift spool is in the float position both ends of the cylinder are
connected to the tank so the loader can follow the contour of the ground. The loader lift circuit can be equipped with
an optional ride control system to allow the loader to be cushioned when traveling. The ride control can be turned on
or off by using the switch on the right-hand console. If the ride control switch is in the on position, there will be no
loader down pressure.
An optional third clam section (H) is available to operate a 4in1 clam bucket or other attachment. This valve spool is
hydraulically pilot operated by a thumb switch located in the loader control handle. If the loader valve is actuated, the
oil returning from the circuit returns through the tank port.
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RAPH12TLB0033EA 4
4. Loader Valve 4H. Clam Spool

4A. Pressure Spike Reducer P2. Oil Supply From Pump
4B. Priority Spool CF. Priority Flow To Steering
4C. Load Check Valve GP. Oil Supply To Clam Pilot
4D. Circuit Relief Valve With Anti Cavitation Check T. Tank
4E. Bucket Spool PB. Power Beyond Flow To Backhoe
4F. Anti Cavitation Check Valve LS. Load Sense Signal From Steering
4G. Lift Spool
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If none of the loader valve spools are activated, oil flows out the power beyond (PB) port of the loader valve. If
equipped, the oil will then flow to an optional uni-directional control valve. On units not equipped with the uni-di-
rectional auxiliary hydraulic system, the power beyond the oil from the loader valve flows directly to the inlet of the
backhoe valve.
Mechanical control backhoe valve – open center

The Manual control backhoe valve (20) is a single casting, mono-block design with an open center type flow path. The
mono-block Manual control backhoe valve body is available with either six or seven spools, depending on whether
the unit had the Extend-A-Hoe option factory installed. On a unit that did not have the Extend-A Hoe option factory
installed, a seventh bolt on section can be added for the optional Extend-A-Hoe feature. An eighth bolt on section
can be added for the optional Bi-directional auxiliary hydraulic function. If the backhoe is not being used the oil will go
through the open center and on to the filter manifold, through the filter and back to the tank. The Swing (20D), Boom
(20G), Dipper (20M) and Bucket (20P) sections all have circuit relief valves with anti-cavitation check valves. The
Boom raise circuit has a low leak valve installed to minimize cylinder drift. The swing section has the anti-rebound
valve connected into the plumbing between the control valve and the swing cylinders. The swing anti-rebound valve
slows the swing system gradually to make the system operate smoothly. Both stabilizer circuits have two-way lock
check valves mounted to the frame and plumbed between the control valve and the cylinders. These lock checks
help hold the stabilizers in either the up or down position.

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RAPH12TLB0069GA 5
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Auxiliary hydraulics – Mechanical backhoe controls

Hydraulically operated attachments can be used with the backhoe. Some of the attachments only require a controlled
oil source and a return, uni-directional (14). Hydraulic hammers and tampers require oil flow in one direction only and
typically require a low pressure return to the reservoir to function properly. Other attachments require pressurized oil
in two directions, bi-directional (40U). Two different auxiliary control options are available. The first auxiliary option
consists of the uni-directional oil flow with a low pressure return only. The second auxiliary option is referred to as the
combo system. The combo system consists of both the uni-directional system and the bi-directional systems.
If equipped, the electrically controlled uni-directional valve is located above the right rear axle. It is connected in the
hydraulic system between the loader and backhoe valve. As the oil exits the loader valve, it can flow to an optional
uni-directional auxiliary valve. When this uni-directional valve is not activated, the oil flows to the inlet of the backhoe
valve. When activated, it can send oil flow to the auxiliary hydraulic coupler at the end of the dipper.
The combo auxiliary option includes the uni-directional auxiliary system as well as a bi-directional auxiliary control
spool in the backhoe valve. The bi-directional system uses the same plumbing on the boom and dipper. When
equipped with the combo hydraulic kit, a pilot operated dual auxiliary return valve is connected to one of the auxiliary
lines. This valve allows the return flow to be diverted directly to the hydraulic filter without having to pass through the
backhoe valve when the uni-directional system is activated.

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RAPH12TLB0069GA 6
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Hydraulic systems - Exploded view
RCPH10TLB005GAM 1
1. Hoses swing control 5. Hydraulic filter 9. Left stabilizer hoses

2. Backhoe valve 6. Loader valve 10. Right stabilizer hoses
3. Left stabilizer load check valve 7. Pressure to backhoe valve 11. Right stabilizer load check valve
4. Return to filter 8. Swing cushion valve
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Hydraulic systems - Exploded view - Hydraulic gear pump, 580N

only
RCPH10TLB007CAM 1
1. Input shaft 6. Quad ring 11. Front housing

2. Retaining ring 7. Pump gear 12. Vent
3. Shaft seal 8. Thrust plate (4) 13. Rear housing
4. Seal 9. Thrust plate seal 14. Cap screws
5. Bearing 10. Load sensing input
NOTE: Torque cap screws (14) to 339 N·m (250 lb ft).
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Hydraulic systems - Exploded view Hydraulic Pump 580SN, 580SN

WT and 590SN
RCPH10TLB003HAM 1
1. Input shaft 6. Vent 11. Kidney plate

2. Retaining ring 7. Rear housing 12. Rotating group, housing
3. Dual shaft seal 8. Cap screws 13. On Stroke Piston Assembly
4. Bearing 9. Swash plate 14. Off Stroke Piston Assembly
5. Front Housing 10. Piston assembly
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Hydraulic systems - Exploded view - Hydraulic gear pump seal,

580N only
RCPH10TLB005GAN 1
1.Input shaft 4. O-ring

2. Retaining ring 5. Seal
3. Seal retainer 6. Seal
NOTE: Seal (6) must be pressed flush with face of recess with lip toward gear as shown.
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Hydraulic systems - Hydraulic schema Regulated manifold

hydraulic schematic, Pilot Controls Only
RCPH10TLB056FAM 1
1. Accumulator 7. Pressure reducing valve

2. Diagnostic port 8. Pilot control on/off solenoid
3. Right-hand stabilizer 9. Orifice
4. Left-hand stabilizer 10. Check valve
5. Extendahoe 11. Auxiliary hydraulics
6. Pattern control selection solenoids 12. Screen
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Hydraulic systems - Exploded view - Regulated manifold, Pilot

Controls only
RCIL10TLB001GAF 1
1. Pattern control selection solenoids 6. Diagnostic port

2. Pressure reducing valve 7. Right stabilizer control solenoids
3. Wire mesh filter 8. Left stabilizer control solenoids
4. Check valve 9. Pilot control on/off solenoid
5. 1.8 mm (0.071 in) orifice 10. Accumulator port
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Hydraulic systems - Exploded view 580N Pilot Machines only
RCPH10TLB006GAM 1
1. Cap for test port "M" (11/16-16 4. Control module 7. Load sense relief valve
ORFS)
2. Pilot manifold test port 5. Gas strut for Pilot Control Adjustment 8. Regulated LS Drain
3. Swing Dampening Valve 6. Regulated Manifold
NOTE: Connect a gauge capable of 344.8 bar (5000 psi) to "M" port (1) using adapter (PN 190119A1). Connect a
gauge capable of 69.0 bar (1000 psi) to the pilot manifold pressure test port (2).
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Hydraulic systems - Exploded view 580SN, 580SN WT and 590SN

machines with pilot controls
RCPH10TLB006GAM 1
1. Cap for test port "M" (11/16-16 4. Control module

ORFS)
2. Pilot manifold test port 5. Gas strut for Pilot Control Adjustment
3. Swing Dampening Valve 6. Regulated Manifold
NOTE: Connect a gauge capable of 344.8 bar (5000 psi) to "M" port (1) using adapter (PN 190119A1). Connect a
gauge capable of 69.0 bar (1000 psi) to the pilot manifold pressure test port (2).
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Hydraulic systems - Cleaning

Special tools
CAS101162A, filter unit, portable.
RCPH10TLB306ABL 1
CAS10192, vacuum pump.
RCPH10TLB454ABL 2
CAS10508, fitting kit.
RCPH10TLB307ABL 3
General information
Contamination in the hydraulic system is a major cause of
the malfunction of hydraulic components. Contamination
is any foreign material in the hydraulic oil. Contamination
can enter the hydraulic system in several ways.
1. When you drain the oil or disconnect any line.
2. When you disassemble a component.
3. From normal wear of the hydraulic components.
4. From damaged or worn seals.
5. From a damaged component in the hydraulic system.
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All hydraulic systems operate with some contamination.

The design of the components in this hydraulic system per-
mits efficient operation with a small amount of contami-
nation. An increase in this amount of contamination can
cause problems in the hydraulic system. The following list
includes some of these problems.
1. Cylinder rod seals leak.
2. Control valve spools do not return to neutral.
3. Movement of control valve spools is difficult.
4. Hydraulic oil becomes too hot.
5. Pump gears, housing, and other parts wear rapidly.
6. Relief valves or check valves held open by dirt.
7. Quick failure of components that have been repaired.
8. Cycle times are slow; machine does not have
enough power.
If your machine has any of these problems, check the hy-
draulic oil for contamination. See types of contamination
below. If you find contamination, use the portable filter to
clean the hydraulic system.
Types of contamination
There are two types of contamination, microscopic and vis-
ible.
1. Microscopic contamination occurs when very fine
particles of foreign material are in suspension in the
hydraulic oil.
2. These particles are too small to see or feel. Micro-
scopic contamination can be found by identification
of the following problems or by testing in a laboratory.
Examples of the problems:
A. Cylinder rod seal leak.

B. Control valve spools do not return to neutral.
C. The hydraulic system has a high operating tem-
perature.
3. Visible contamination is foreign material that can be
found by sight, touch, or odor. Visible contamination
can cause a sudden failure of components. Exam-
ples of visible contamination:
A. Particles of metal or dirt in the oil.

B. Air in the oil
C. The oil is dark and thick.
D. The oil has an odor of burned oil.
E. Water in the oil. See flushing water from the
hydraulic system, step 23.
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Cleaning the hydraulic system

1. Prepare the portable filter by doing the following
steps:
A. Remove all the hydraulic oil from the inlet and
outlet hoses for the portable filter.
B. Remove the filter element from the portable fil-
ter.
C. Remove all hydraulic oil from the portable filter.
D. Clean the inside of the housing for the filter
element.
2. You must know whether the contamination is micro-
scopic or visible. See types of contamination .
3. If the contamination is microscopic:
A. Check the maintenance schedule for the ma-

chine to learn when the hydraulic oil must be
changed. If needed, change the hydraulic oil.
B. Complete steps 6 through 35.
4. If the contamination is visible:
A. Change the hydraulic oil and hydraulic filter.

Refer to the Operator's manual for more de-
tails.
B. Complete steps 5 through 35.
5. Check the amount of contamination in the hydraulic
system by doing the following steps:
A. Disassemble one cylinder in two different cir-

cuits. Check for damage to seals, scoring of
the cylinder wall, etc. Repair the cylinders as
necessary.
B. If, in your judgment, the damage to the cylin-
ders was caused by sever contamination and
is not the result of normal wear, it is neces-
sary to remove, clean and repair valves, pump,
lines, cylinders, hydraulic reservoir, etc. in the
hydraulic system.
6. Remove the breather from the reservoir and connect
the vacuum pump to the opening. Start the vacuum
pump.
7. Loosen and remove the drain plug from the reservoir.
8. Using the fitting kit, install the valve in the hole for the
drain plug. Make sure that the valve is closed.
9. Stop the vacuum pump.
10. Connect the inlet hose for the portable filter to the
valve that is installed in the hole for the drain plug.
11. Disconnect the vacuum pump from the hydraulic
reservoir air breather hose. Remove the filler cap.
12. Install the outlet hose for the portable filter in the hy-
draulic reservoir filler neck.
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13. Open the valve that is installed in the hole for the
drain plug.
14. Move the switch for the portable filter to the ON po-
sition. Start and run the engine at 1500 RPM.
15. Run the portable filter for 10 min.
16. Continue to run the portable filter. Increase the en-
gine speed to full throttle. Heat the oil to operating
temperature by doing the following steps:
Complete this procedure on variable pump machines
when the temperature is below 40 degrees F (4 de-
grees C) and the engine has been warmed up.
1. Leave the boom in the transport position with
the transport pin installed.
2. Activate the pilot control switch, if equipped
with pilot controls.
3. Raise the engine speed between 1600 and
1800 rpm.
4. Place and hold the boom control in the down
position.
5. Cycle the functions for approximately 30 sec-
onds.
6. Release the controls for approximately 15 sec-
onds.
7. Repeat steps until the desired oil temperature
of 120 degrees F (48 degrees C) is reached.
17. Continue to run the engine at full throttle. Continue
to run the portable filter.
18. Operate each hydraulic circuit to completely extend
and retract the cylinders. Continue to operate each
hydraulic circuit two times, one after the other for 45
min.
19. Decrease the engine speed to low idle.
20. Continue to run the portable filter for 10 min.
21. Stop the portable filter.
22. Stop the engine.
23. Remove the hose from the hydraulic reservoir.
24. Close the valve that is installed in the hole for the
drain plug.
25. Disconnect the inlet hose for the portable filter from
the valve. Remove the outlet hose from the reservoir
filler neck and replace filler cap.
26. Connect a vacuum pump to the breather hose of the
hydraulic reservoir.
27. Start the vacuum pump.
28. Remove the valve from the hole for the drain plug.
29. Install the drain plug.
30. Stop the vacuum pump. Disconnect the vacuum
pump from the opening in the reservoir and install
the breather.
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31. Remove the hydraulic filter elements from the ma-

chine.
32. Install new hydraulic filter elements on the machine.
33. Start the engine. Check for oil leakage around the
new hydraulic filters.
35. Check the oil level in the hydraulic reservoir. Add oil
as required. See Section 1002 for specifications.
Flushing water from the hydraulic system

1. Start and run the engine at 1500 RPM.
2. Completely retract the cylinders of all attachments on
the machine. Swing the boom to the right, the right
cylinder will be fully retracted and the left will be fully
extended.
NOTE: If retracting the cylinder rods causes the attachments to be raised, block the attachments in place before
proceeding to the next step!
NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent
the attachment from falling.
3. Stop the engine.
4. Turn the key switch to the ON position.
5. Turn the Pilot Controls switch to the ON position.
6. Move each Pilot Control lever in each direction to
relieve pressure.
7. Loosen and remove the filler cap from the reservoir.
8. Drain the hydraulic oil from the reservoir.
A. See capacity specifications.

B. Have available acceptable equipment to drain
the hydraulic oil.
C. Remove the drain plug from the bottom of the
reservoir.
chine.
11. Install the drain plug in the bottom of the reservoir.
12. Fill the hydraulic reservoir with hydraulic fluid.
13. Disconnect the line from the open end and closed
end of each cylinder.
14. Be sure all control levers are in the neutral position.
NOTICE: Check the oil level in the hydraulic reservoir frequently while doing step 16. Have another person hold a
container under the hydraulic lines while you do step 16.
16. Slowly move each control lever in both directions un-
til oil begins to flow from the open line. Hold the con-
trol lever in place until clean oil flows from the open
line.
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18. Connect the system line to the closed end of each
cylinder.
19. Connect a suitable drain line to the open end of each
cylinder and place the other end in an acceptable
container for contaminated oil.
20. Start the engine and run the engine at low idle.
21. Slowly and completely extend all cylinders. As the
piston rod comes in/out of the cylinder, oil will be
pushed out of the open end of the cylinders.
NOTE: Any attachment or part of an attachment that is raised must be supported with acceptable equipment to prevent
the attachment from falling.
22. Support any attachments that will be in the raised
position.
24. Disconnect the drain lines and connect the system
lines to the cylinders.
as required.
26. Install the filler cap on the reservoir.
chine.
29. Start and run the engine at 1500 RPM, operate each
hydraulic circuit to completely extend and retract the
cylinders.
30. Stop the engine and check for leaks. Check the oil
level in the hydraulic reservoir. Add oil as required.
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Hydraulic systems - Disassemble - Regulated manifold

1. Remove the pressure reducing valve.
RCPH10TLB371ABL 1
2. Remove the check valve and orifice.
RCPH10TLB443ABL 2
3. Remove the accumulator.
RCPH10TLB372ABL 3
4. Remove the nut and solenoid for the cutoff valve.
RCPH10TLB373ABL 4
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5. Loosen and remove the cutoff valve.
RCPH10TLB374ABL 5
6. Remove the nut and solenoid for the pattern control

selection valves.
RCPH10TLB376ABL 6
7. Loosen and remove the pattern control selection

valves.
RCPH10TLB378ABL 7
8. Remove the stabilizer solenoid mounting screws.
RCPH10TLB381ABL 8
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9. Remove the stabilizer solenoids.
RCPH10TLB382ABL 9
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Hydraulic systems - Assemble - Regulated manifold

1. Replace all O-rings and backup rings.
2. Lubricate all O-rings with hydraulic oil before in-
stalling.
RCPH10TLB383ABL 1
3. Install the stabilizer solenoids into the manifold.
RCPH10TLB382ABL 2
4. Install and torque the stabilizer mounting screws to

20 N·m (15 lb ft).
RCPH10TLB384ABL 3
5. Install the pattern control selection valves into the

manifold.
RCPH10TLB380ABL 4
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6. Torque the pattern control selection valves to 20 N·m

(15 lb ft).
RCPH10TLB385ABL 5
7. Install the solenoids on the pattern control selection

valves.
NOTE: Make sure the connectors are towards the bottom
of the manifold.
RCPH10TLB386ABL 6
8. Torque the pattern control selection solenoids to 1.7

- 2.2 N·m (15 - 19 lb in).
NOTICE: Overtorquing will cause the solenoid to bind and
stick.
RCPH10TLB387ABL 7
9. Install the orifice (1) into the manifold.

10. Install the O-ring (2) onto the check valve (3).
RCPH10TLB443ABL 8
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11. Install the check valve into the manifold with the small
holes facing away from the pressure reducing valve.
RCPH10TLB444ABL 9
12. Install the pressure reducing valve into the manifold.

13. Torque the pressure reducing valve to 20 N·m (15 lb
ft).
RCPH10TLB388ABL 10
14. Install the cutoff valve into the manifold.
RCPH10TLB375ABL 11
15. Torque the cutoff valve to 20 N·m (15 lb ft).
RCPH10TLB389ABL 12
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16. Torque the cutoff valve solenoid to 1.7 - 2.2 N·m (15
- 19 lb in).
NOTICE: Overtorquing will cause the solenoid to bind and
stick.
RCPH10TLB390ABL 13
17. Install and tighten the accumulator into the manifold.

Maximum applied torque 45 N·m (32 lb ft).
RCPH10TLB391ABL 14
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Hydraulic systems - Prepare - Machine Preparation, 580N Pilot

machines
RCPH10TLB059FAM 1
Legend
(1) Pump (5) Tee Connector 84238739
(2) Loader Valve (6) Tube Assembly, Pump to Valve
(3) EF Pressure Port (7) Connector 3/8 ORFS-ORB 3/8
(4) Flow Meter Connection
NOTE: New ORFS flowmeter hoses will be required with this procedure.
NOTE: Remove hydraulic tank filler cap and place the flowmeter outlet hose (6) below oil level, SECURE HOSE.
NOTE: Make copies of the Flowmeter Check Sheet in rear of this section and use it to record the readings.
hoe in the transport position. Lower the loader
bucket to the floor.
2. Stop the engine. Turn the key switch and the pilot
control switch to the ON position.
3. Operate the pilot controls and loader controls to re-
lieve any pressure in the system.
4. Connect a gauge capable of 69 bar (1000 psi) to the
pilot pressure test port.
5. Use an 11/16 - 16 ORFS fitting to connect a gauge
capable of measuring 345 bar (5000 psi) to the "M"
port on the backhoe valve. Use ORFS fitting part
number 190119A1.
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6. Remove pressure testing adapter from the pump EF

port (2), connect flowmeter input hose (3) to the fit-
ting.
7. Remove the screen from the reservoir and secure the
flowmeter return hose (6) below the oil level.
8. The oil must be at operating temperature. To heat
the oil:
A. With engine running at full throttle, close the
relief valve on the flowmeter to a least 103 bar
(1500 psi).
B. Hold the loader control lever in the ROLLBACK
position of 15 seconds.
C. Put the loader control lever in the NEUTRAL
position for 15 seconds.
D. Repeat steps (B) and (C) until the temperature
of the oil is 52 °C (125 °F) or the side of the
reservoir is very warm.
Next operation:
Hydraulic systems - Test Pressure Test, 580N Pilot machines (35.000).
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Hydraulic systems - Test Pressure Test, 580N Pilot machines

See Hydraulic systems - Check - Flowmeter Check Sheet, 580N Pilot machines (35.000) for form to record test
results.
Prior operation:
Hydraulic systems - Prepare - Machine Preparation, 580N Pilot machines (35.000).
Pilot Manifold Pressure Test
Test 1A
1. Run engine at high idle. Do not activate any backhoe
controls.
2. Monitor flowmeter. Record flow regulator pressure
on Flowmeter Check Sheet.
Test 1B
1. Enable backhoe pilot system switch.
2. Place any backhoe function on demand.
3. Monitor flowmeter. Record pilot pressure on
Flowmeter Check Sheet.
NOTE: A pressure reading of 24 - 34.5 bar (348.0 - 500.3 psi) is expected. If pressure is not to specification, replace
pressure reducing valve.
Backhoe Relief
4. Run engine at high idle. Retract Extendahoe if
equipped or hold Boom in raised position over relief.
5. Slowly open flowmeter load valve until pressure
reads zero.
Test 2A
1. Slowly close flowmeter load valve.
2. Monitor flowmeter. Record pressure when flow drops
by several l/min (gpm). Record results on Flowmeter
Check Sheet.
Test 2B
1. Continue to close load valve on flowmeter.
2. Monitor flowmeter. When flow reaches 0 l/min (gpm),
a pressure reading of 227 - 235 bar (3292 - 3408 psi)
is expected. Record results on Flowmeter Check
Sheet.
NOTE: If pressure is not in specification, adjust main relief valve. If readings from test 2A are not within 10 percent
of 2B reading, replace relief valve.
Pump Efficiency Test
Test 3A
3. Hold loader on demand and open the load valve. Ad-
just engine speed to 2000 RPM.
4. Monitor flowmeter. Record results on Flowmeter
Check Sheet.
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Test 3B
1. Continue to run engine at 2000 RPM. Slowly close
load valve until pressure is 138 bar (2001.0 psi).
Check Sheet.
3. Divide the flow reading at 138 bar (2001.0 psi) by
recorded flow reading at 0.0 bar (0 psi).
NOTE: Pump efficiency is calculated by multiplying result by 100. If pump efficiency is greater than 70 percent, pump
is good. Continue to next test. If pump efficiency is less than 70 percent, repair or replace pump before continuing to
next test.
4. Run engine at 2000 RPM. Increase pressure on
flowmeter to 138 bar (2001.0 psi).
Loader Control Valve Leak Test

flowmeter to 138 bar (2000 psi).
Test 4A
1. Raise loader. Hold loader in raised position.
2. Monitor flowmeter. Record l/min (gpm) on Flowmeter
Check Sheet.
Test 4B
1. Lower loader. Hold loader in lower position.
2. Monitor flowmeter. Record l/min (gpm) results on
Test 4C
1. Position loader approximately 45.7 cm (18 in) above
ground level. Hold bucket in rollback position.
Test 4D
1. Hold bucket in dump position.
Test 4E
1. Hold clam in open position.
Test 4F
1. Close clam and hold in closed position.
NOTE: Compare test results from Test 3B and Tests 4A thru 4F. If results vary more than 3.8 l/min (1 US gpm), a
problem in circuit exists.
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NOTE: If equipped with uni-directional valve, ensure valve is off.
Backhoe Control Valve Leak Test
Test 5A
1. Position backhoe to left side.
Test 5B
1. Position backhoe to right side.
Test 5C
1. If equipped with extend-a-hoe option, position out-
ward and hold in position.
Test 5D
1. If equipped with extend-a-hoe option, retract and
hold in position.
Test 5E
1. Raise left stabilizer. Hold in position.
Test 5F
3. Raise right stabilizer. Hold in position.
Test 5G
NOTE: When lowering stabilizers, lower evenly to full stroke, then raise.
1. Lower left stabilizer. Hold in position.
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Test 5H
1. Lower right stabilizer. Hold in position.
Test 5I
1. Roll backhoe bucket to dump position. Hold in posi-
tion.
Test 5J
1. Roll backhoe bucket to dig position. Hold in position.
Test 5K
1. Position dipper in full extended position. Hold in po-
sition.
Test 5L
1. Position dipper in full position. Hold in position.
Test 5M
1. Position boom in lower position. Hold in position.
Test 5N
1. Position boom in raised position. Hold in position.
Test 5O
1. If equipped with bi-directional auxiliary hydraulic, set
selector switch to Bi-Aux. Unhook the quick discon-
nect couplers or cap lines. Hold button in out posi-
tion.
Test 5P
1. Reverse direction on bi-directional valve.
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NOTE: Compare test results from Test 3B and Tests 5A thru 5P. If results vary more than 3.8 l/min (1 US gpm), a
Steering and Bucket Coupler Valve Flow Test

3. Install a "T" fitting a "CF" port on pump, see Variable
displacement pump - Sectional view (35.106) for
more details. Connect flowmeter to "T" fitting.
Test 6A
1. Run engine at high idle. Close load valve on flowme-
ter.
2. Record bar (psi) results on Flowmeter Check Sheet.
Test 6B
1. Turn steering wheel to full right. Hold against stop.
2. Open flowmeter load valve to 69.0 bar (1000 psi).
3. With steering wheel held against stop, slowly close
load valve.
4. Monitor flowmeter. When flow begins to decrease
by several l/min (gpm), record bar (psi) results on
Test 6C
1. Continue to slowly close load valve.
2. Monitor flowmeter. When flow reaches 0.0 l/min
(0 US gpm), record bar (psi) results on Flowmeter
Check Sheet.
NOTE: A pressure reading of 162 - 172 bar (2349 - 2494 psi) is expected.
Test 6D
1. Open flowmeter load valve to fully open position.
2. If equipped with front or rear hydraulic coupler, en-
gage. Slowly close flowmeter load valve.
Test 6E
1. Continue to slowly close flowmeter load valve.
Check Sheet.
NOTE: A pressure reading of 162 - 193 bar (2349 - 2800 psi) is expected. If pressure is not to specification, adjust
quick coupler relief valve.
Steering and Bucket Lock Valve Leak Test

3. Turn steering wheel to full left. Hold against stop.
4. Close flowmeter load valve to 124.1 bar (1800 psi).
Adjust engine speed to 2000 RPM.
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Test 7A
Test 7B
3. Extend backhoe bucket fully to dump position. Place
loader and backhoe bucket on ground.
Test 7C
1. Retract loader lock pins.
Test 7D
1. Extend loader lock pins.
2. Record l/min (gpm) results on Flowmeter Check
Sheet.
Test 7E
1. Retract backhoe bucket lock pins.
Test 7F
1. Extend backhoe bucket lock pins.
NOTE: If flow readings of tests vary more than 3.8 l/min (1 US gpm), a problem in that circuit exists.
3. Open flowmeter valve. Stop engine. Inspect for re-
pairs and repair as necessary. Retest circuit.
4. Remove all test equipment. Connect all hydraulic
systems. Ensure hydraulic fluid level is to specifica-
tion. Add fluid as required.
Backhoe Valve Flow Regulator Test

5. Connect a gauge ( 69.0 bar (1000 psi) minimum) to
the M port on the Backhoe Control valve. Install test
point in the LS port on the Backhoe Valve.
6. Connect a gauge ( 69.0 bar (1000 psi) minimum) to
lead sense test port. Install a shut-off valve in hose.
7. Set engine speed to 1950 RPM. Do not activate any
controls.
Test 8A
1. Monitor M port pressure gauge. Record pressure on
Flowmeter Check List.
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Test 8B
1. Monitor load sense port pressure gauge. Record
pressure on Flowmeter Check List.
NOTE: Subtract Test 8B result from 8A result. Difference is backhoe flow regulating setting. Record result on Flowme-
ter Check List.
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Hydraulic systems - Check - Flowmeter Check Sheet, 580N Pilot

machines
Provide the following information:
Owner:_______________ Model:_______________ Serial No.:_______________
Date:_______________ Hours:_______________
NOTE: Prior to testing, machine must be prepped and establish a minimum oil temperature of 51 °C (123.8 °F). See
Hydraulic systems - Prepare - Machine Preparation, 580N Pilot machines (35.000) for procedure.
Test 1- Pilot Manifold Pressure
Test 1A - flow regulator pressure __________bar __________psi
Test 1B - pilot pressure __________bar __________psi
Notes:
Test 2- Backhoe Relief
Test 2A - Relief opens @: __________bar __________psi
Test 2B __________bar __________psi
Notes:
Test 3- Pump Efficiency
Test 3A flow reading __________l/min __________gpm @ minimum
Test 3B flow reading __________l/min __________gpm @ 2000 psi
Test 3B divided by Test 3A = Flow resultant __________l/min __________gpm
Flow resultant multiplied by 100 = Pump efficiency __________%

Pump efficiency is calculated by multiplying result by 100. If pump efficiency is greater than 70 percent, pump is
good. If pump efficiency is less than 70 percent, repair or replace pump.
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Test 4- Loader Control Valve Leakage
Test 4A - Loader Raised __________l/min __________gpm
Test 4B - Loader Lowered __________l/min __________gpm
Test 4C - Bucket Rollback __________l/min __________gpm
Test 4D - Bucket Dump __________l/min __________gpm
Test 4E - Clam Open __________l/min __________gpm
Test 4F - Clam Closed __________l/min __________gpm
Notes:
Test 5- Backhoe Control Valve Leakage @ 2000 RPM
Test 5A - Swing Left __________l/min __________gpm
Test 5B - Swing Right __________l/min __________gpm
Test 5C - Extend-a-hoe extended __________l/min __________gpm
Test 5D - Extend-a-hoe retracted __________l/min __________gpm
Test 5E - Left stabilizer raised __________l/min __________gpm
Test 5F - Right stabilizer raised __________l/min __________gpm
Test 5G - Left stabilizer lowered __________l/min __________gpm
Test 5H - Right stabilizer lowered __________l/min __________gpm
Test 5I - Bucket in dump position __________l/min __________gpm
Test 5J - Bucket in curl position __________l/min __________gpm
Test 5K - Dipper extended __________l/min __________gpm
Test 5L - Dipper retracted __________l/min __________gpm
Test 5M - Boom lowered __________l/min __________gpm
Test 5N - Boom raised __________l/min __________gpm
Test 5O - Bi-directional auxillary forward __________l/min __________gpm
Test 5P - Bi-directional auxillary reversed __________l/min __________gpm
Notes:
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Test 6- Steering and Bucket Lock Valve Flow
Test 6A - Steering standby __________bar __________psi
Test 6B - Steering relief - Begins to open @ __________bar __________psi
Test 6C - Steering relief - Fully open @ __________bar __________psi
Test 6D - Coupler relief - Begins to open @ __________bar __________psi
Test 6E - Coupler relief - Fully open @ __________bar __________psi
Notes:
Test 7- Steering and Bucket Lock Valve Flow @ High Idle
Test 7A - Steering right __________l/min __________gpm
Test 7B - Steering left __________l/min __________gpm
Test 7C - Loader bucket retract __________l/min __________gpm
Test 7D - Loader bucket extend __________l/min __________gpm
Test 7E - Backhoe bucket retract __________l/min __________gpm
Test 7F - Backhoe bucket extend __________l/min __________gpm
Notes:
Test 8- Backhoe Valve Flow Regulator
Test 8A - __________bar __________psi
Test 8B - __________bar __________psi
Test 8A minus Test 8B = Valve flow regulator setting __________bar __________psi
Notes:
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Hydraulic systems - Prepare - Machine Preparation, 580N

Mechanically Controlled machines
RCPH10TLB059FAM 1
Legend
(1) Pump (5) Tee Connector 84238739
(2) Loader Valve (6) Tube Assembly, Pump to Valve
(3) EF Pressure Port (7) Connector 3/8 ORFS-ORB 3/8
(4) Flow Meter Connection
NOTE: New ORFS flowmeter hoses will be required with this procedure.
NOTE: Remove hydraulic tank filler cap and place the flowmeter outlet hose (6) below oil level, SECURE HOSE.
NOTE: Make copies of the Flowmeter Check Sheet in rear of this section and use it to record the readings.
2. Stop the engine. Turn the key switch and the pilot
control switch to the ON position.
3. Operate the pilot controls and loader controls to re-
lieve any pressure in the system.
pilot pressure test port.
5. Use an 11/16 - 16 ORFS fitting to connect a gauge
capable of measuring 345 bar (5000 psi) to the "M"
port on the backhoe valve. Use ORFS fitting part
number 190119A1.
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6. Remove pressure testing adapter from the pump EF

port (2), connect flowmeter input hose (3) to the fit-
ting.
7. Remove the screen from the reservoir and secure the
flowmeter return hose (6) below the oil level.
the oil:
A. With engine running at full throttle, close the
relief valve on the flowmeter to a least 103 bar
(1500 psi).
B. Hold the loader control lever in the ROLLBACK
position of 15 seconds.
C. Put the loader control lever in the NEUTRAL
D. Repeat steps (B) and (C) until the temperature
Next operation:
Hydraulic systems - Test Pressure Test, 580N Mechanically Controlled machines (35.000).
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Hydraulic systems - Test Pressure Test, 580N Mechanically

Controlled machines
See Hydraulic systems - Check - Flowmeter Check Sheet, 580N Mechanically Controlled machines (35.000)
for form to record test results.
Prior operation:
Hydraulic systems - Prepare - Machine Preparation, 580N Mechanically Controlled machines (35.000).
Backhoe Relief
1. Run engine at high idle. Retract Extendahoe if
equipped or hold Boom in raised position over relief.
reads zero.
Test 1A
Check Sheet.
Test 1B
2. Monitor flowmeter. When flow reaches 0 l/min (gpm),
a pressure reading of 227 - 235 bar (3292 - 3408 psi)
is expected. Record results on Flowmeter Check
Sheet.
Pump Efficiency Test
Test 2A
Check Sheet.
Test 2B
load valve until pressure is 138 bar (2000 psi).
Check Sheet.
3. Divide the flow reading at 138 bar (2000 psi) by
recorded flow reading at 0.0 bar (0 psi).
next test.
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Loader Control Valve Leak Test
Test 3A
Check Sheet.
Test 3B
Test 3C
Test 3D
Test 3E
Test 3F
Backhoe Control Valve Leak Test
Test 4A
Test 4B
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Test 4C
Test 4D
hold in position.
Test 4E
Test 4F
Test 4G
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Test 4H
Test 4I
tion.
Test 4J
Test 4K
sition.
Test 4L
Test 4M
Test 4N
Test 4O
1. If equipped with bi-directional auxiliary hydraulics,
set the selector switch to Bi-Aux. Unhook the quick
disconnect couplers or cap lines. Hold button in the
out position.
Test 4P
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Steering and Bucket Coupler Valve Flow Test

3. Install a "T" fitting a "CF" port on pump, see Variable
Test 5A
ter.
Test 5B
load valve.
Test 5C
Check Sheet.
Test 5D
Test 5E
Check Sheet.
Steering and Bucket Coupler Valve Leak Test

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Test 6A
Test 6B
Test 6C
Test 6D
Sheet.
Test 6E
Test 6F
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Hydraulic systems - Check - Flowmeter Check Sheet, 580N

Mechanically Controlled machines
Date:_______________ Hours:_______________
NOTE: Prior to testing, machine must be prepped and establish a minimum oil temperature of 51 °C (123.8 °F).
See Hydraulic systems - Prepare - Machine Preparation, 580N Mechanically Controlled machines (35.000) for
procedure.
Test 1B __________bar __________psi
Notes:

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Notes:
Notes:
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Notes:
Notes:
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Hydraulic systems - Prepare Machine Preparation, All 580SN,

580SN WT and 590SN machines
RCPH10TLB058FAM 1
Legend
(1) Pump (4) Tee Connector
(2) To System (5) Pressure Port
(3) Attenuator Hose (6) Flowmeter Hose
NOTICE: If the machine is equipped with pilot controls, the pure closed center plug kit must be installed in the back-
hoe valve inlet before running the following tests. THIS IS ONLY TRUE FOR SUPER N MACHINES. INSTALLING
A CLOSED CENTER PLUG IN A 580N COULD RESULT IN PUMP DAMAGE. The kit should be removed from the
machine after these tests, and the original components which provide the constant flow closed center feature, re-in-
stalled. The pure closed center plug kit is part number 87447426. The kit will include a new “spool,” a new o-ring,
and a different cap. All of these components must be installed together for proper operation. If the new spool is used
with the cap that came with the machine, improper operation will result.
1. Park machine on level, firm surface. Position back-
hoe in transport position. Lower bucket to ground.
2. Stop engine. Turn ignition switch and pilot control
switch ON. Operate pilot and loader controls to re-
lieve pressure in system.
3. Connect pressure gauge ( 69 bar (1000 psi) mini-
mum) to pilot pressure test port.
Machines with Mechanical Controls

4. Remove diagnostic couple fitting and install a tee fit-
ting. From attenuator hose, attach flowmeter input
to the end of attenuator hose. It may make access
easier if the attenuator hose is unclamped.
5. Remove screen from reservoir. Secure flowmeter
return hose below oil level.
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ting. From attenuator hose, attach flowmeter input to
the end of attenuator hose.
Machines with Mechanical Controls

ting. From attenuator hose, attach flowmeter input
to the end of attenuator hose. It may make access
easier if the attenuator hose is unclamped.
ting. From attenuator hose, attach flowmeter input to
the end of attenuator hose.
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Hydraulic systems - Test Pressure Test, All 580SN, 580SN WT and

590SN machines
See Hydraulic systems - Check Flowmeter Check Sheet, All 580SN, 580SN WT and 590SN machines (35.000)
for form to record test results.
Prior operation:
Hydraulic systems - Prepare Machine Preparation, All 580SN, 580SN WT and 590SN machines (35.000).
Pilot Manifold Pressure Test - Pilot controlled machines only
Test 1A
1. Enable backhoe pilot system switch.
2. Place any backhoe function on demand.
3. Monitor flowmeter. Record pilot pressure on
NOTE: A pressure reading of 24 - 34.5 bar (348.0 - 500.3 psi) is expected. If pressure is not to specification, replace
pressure reducing valve.
Backhoe Relief - Machines without PowerLift

1. Run engine at high idle. Hold Extendahoe on retract
if equipped or hold Boom in raised position over re-
lief.
reads zero.
Test 2A
Check Sheet.
Test 2B
2. Monitor flowmeter. When flow reaches zero, a pres-
sure reading of 234 - 242 bar (3400 - 3500 psi) is ex-
pected. Record results on Flowmeter Check Sheet.
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RCPH11TLB002GAM 1
(1) Normal Relief (2) Power Lift Relief
Test 2C
Machines With Power Lift

1. Turn the seat toward the rear (Backhoe).
3. Monitor flowmeter. When flow reaches zero, a pres-
sure reading of 234 - 242 bar (3400 - 3500 psi) is ex-
pected. Record results on Flowmeter Check Sheet.
NOTE: If pressure is not in specification, adjust normal relief valve on Power Lift control valve.
4. Activate Power Lift.
580SN and 590 machines

1. Monitor flowmeter. When flow reaches zero , a pres-
sure reading of 246 - 253 bar (3575 - 3675 psi) is
expected.
Record results on Flowmeter Check Sheet.
NOTE: If pressure is not in specification, adjust Power Lift relief valve.
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580SN WT machines
1. Monitor flowmeter. When flow reaches zero , a pres-
sure reading of 257 - 264 bar (3730 - 3830 psi) is
expected.
Record results on Flowmeter Check Sheet.
NOTE: If pressure is not in specification, adjust Power Lift relief valve on the Power Lift control valve.
Pump Efficiency Test - All

1. Remove the torque control supply tube (1) and cap
574342 the torque control supply tube ports (2) and
(3) on pump.
NOTE: All Super N machines are equipped with a torque regulation feature to control engine loading from the hydraulic
systems. To properly test the variable displacement pump, this feature needs to be disabled. This feature can be
disabled without changing any settings by simply removing torque control supply tube and cap both of the open ports.
RCPH11TLB001GAM 2
Test 3A
Check Sheet.
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Test 3B
load valve until pressure is 138 bar (2000 psi).
Check Sheet.
3. Divide the flow reading at 138 bar (2000 psi) by
recorded flow reading at 0 bar (0 psi).
next test.
Loader Control Valve Leak Test - All
Test 4A
Check Sheet.
Test 4B
Test 4C
Test 4D
Test 4E
Test 4F
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Backhoe Control Valve Leak Test - All
Test 5A
Test 5B
Test 5C
Test 5D
hold in position.
Test 5E
Test 5F
Test 5G
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Test 5H
Test 5I
tion.
Test 5J
Test 5K
sition.
Test 5L
Test 5M
Test 5N
Test 5O
1. If equipped with bi-directional auxiliary hydraulic, un-
hook quick disconnect couplers or cap lines. Hold
button in out position.
Test 5P
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Steering and Bucket Coupler Valve Flow Test - All

3. Install a "T" fitting a "D" port on pump, see Variable
Test 6A
ter.
Test 6B
load valve.
Test 6C
Check Sheet.
Test 6D
Test 6E
Check Sheet.
Steering and Bucket Coupler Valve Leak Test - All

Test 7A
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Test 7B
Test 7C
Test 7D
Sheet.
Test 7E
Test 7F
NOTE: For Pilot Controlled machines, replace the closed center plug in the backhoe valve with the standard flushing
valve components removed earlier.
Low Pressure Standby Regulator- Single gauge method

All 580SN, 580SN-WT and 590SN with Power Lift.
1. Warm the machine to 50 °C (120 °F). To warm the
engine:
• Machines with mechanical controls, meter the
stabilizer functions to maximum engine load.
• Pilot Controlled machines, stall the boom down
function or stall a single function while moving
a secong function.
2. After the oil has reached 50 °C (120 °F), stop the
engine.
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3. Connect a gauge capable of 500 psi to the end of

the attenuator hose.
4. Remove the hose from the end of the load sense
compensator at the back of the pump and plug the
open hose end. Leave the port on the pump com-
pensator open.
5. Place a bucket under the open load sense compen-
sator port or connect a hose to the open port and run
into the fill neck of the hydraulic reservoir.
6. Start the machine and stall a single function.
7. The pressure displayed on the gauge at the attenu-
ator hose is the pump margin pressure. Acceptable
pump margin is 19 - 21 bar (275 - 305 psi).
8. Reconnect the LS hose to the LS port on the pump
compensator.
Low Pressure Standby Regulator - Two gauge method

All 580SN, 580SN-WT and 590SN with mechanical con-
trols and Power Lift.
1. Connect a gauge capable of 500 psi to the end of
the attenuator hose and a second 500 psi gauge to
the diagnostic port on the Power Lift valve.
engine:
a secong function.
3. Stall the stabilizer function and record the pressure
on both gauges.
4. To find the pump margin, subtract the load sense
pressure from the attenuator hose pressure.
Low Pressure Standby Regulator - Two gauge method

All 580SN, 580SN-WT and 590SN with Pilot controls and
Power Lift.
1. Connect a gauge capable of 500 psi to the end of the
attenuator hose and a second 500 psi gauge to the
load sense diagnostic port on the Power Lift valve.
engine:
a second function.
3. Set the engine to 2000 RPM. Do not operate any
functions. Record the pressures at the attenuator
hose gauge and the load sense gauge at Power Lift
valve.
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4. To find the pump margin, subtract the load sense

pressure from the attenuator hose pressure.
Pump Margin Adjustment

5. If the load sense margin is not within specifications,
the setting can be adjusted by loosening the lock nut
at the top of the load sense (1)compensator and ad-
justing the set screw. Tightening the set screw in-
creases the margin and loosening the set screw de-
creases the pump margin.
RCPH11TLB001GAM 3
(1) Load Sense - Margin Control

(2) Torque Control Screw
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High Pressure Cutoff

(HPCO) - 580SN Mechanical without Power Lift
1. Connect a pressure gauge capable of 5000 psi to
the end of the attenuator hose.
2. Warm the engine to 50 °C (120 °F). To warn the en-
gine, set the throttle to full speed and meter the sta-
bilizer control to maximum engine load.
3. Stall the stabilizer, extendahoe or loader lift and
record the pressure on the gauge. This is the HPCO
pressure (machine stall pressure). The acceptable
pressure range is 234 - 241 bar (3400 - 3500 psi).
If the HPCO is out of range, adjust the HPCO screw
on the pump compensator. This is the same location
as the LS adjustment for machines with Power Lift.
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Hydraulic systems - Check Flowmeter Check Sheet, All 580SN,

580SN WT and 590SN machines
Date:_______________ Hours:_______________
NOTE: Prior to testing, machine must be prepped and establish a minimum oil temperature of 51 °C (123.8 °F). See
Hydraulic systems - Prepare Machine Preparation, All 580SN, 580SN WT and 590SN machines (35.000) for
procedure.
Test 1- Pilot Manifold Pressure
Test 1B - pilot pressure __________bar __________psi
Notes:
Test 2B __________bar __________psi
Notes:

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Notes:
Notes:
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Notes:
Notes:
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Hydraulic systems - Adjust Torque Control Adjustment, 580SN,

580SN WT and 590SN machines with Mechanical Controls
NOTICE: This procedure should be followed carefully and should ONLY be performed as a last step in the trou-
bleshooting/repair process. Improper adjustment will damage the hydraulic system.
For this test the machine will see pressure of at least 221
bar (3200 psi). A 75 US gpm flowmeter (p/n CAS10280)
will be used. If the flowmeter is equipped with pipe thread
connections, these fittings will have to be removed and re-
placed with ORFS connections (p/n 87303844). Also, hose
with a minimum 275 bar (4000 psi) working pressure will
need to be used. It is recommended that the hoses be
made 8 ft to 12 ft long with #16 female ORFS (1 7/16-12)
ends.
1. Remove the tee from the pressure outlet at the rear
of the pump and install a plug 9847694 in the open
end of the tee and tighten.
2. Attach one end of a test hose to the adapter fitting at
the pressure outlet of the pump. Connect the other
end of the hose to the inlet port of the test flowmeter.
3. Remove the loader valve return hose from the tee at
the rear of the filter. Install a plug in the end of the
return hose and tighten.
4. Connect the end of the second test hose at the open
port and the other end to the outlet of the flowmeter.
5. Warn the machine to 49 °C (120 °F). To warm the
machine start the engine and set the throttle to 2000
RPM. Adjust the load valve at the service flowmeter
to 172 - 207 bar (2500 - 3000 psi). Allow the ma-
chine to run in this condition until the temperature is
reached.
6. Stop the engine.
7. Remove the torque controls supply tube from the
pump.
8. Cap the open adapter fitting at the variable relief
valve on the top of the pump using 574342.
9. Connect a hose from the open port at the torque con-
trol compensator and run into the fill neck of the hy-
draulic reservoir.
10. Connect a gauge capable of 34.5 bar (500 psi) to
the diagnostic fitting at the power lift valve.
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RCPH10TLB013FAM 1
(1) Torque Control Variable Relief (5) Pressure Compensator (580SN with Power
Lift) Load Sense Compensator (580SN with
Power Lift, 580SN WT, 590SN)
(2) Torque Control Supply Tube (6) Torque Control Compensator
(3) Gauge Port (7) Load Sense Port
(4) Mode Selection Solenoid
Checking Torque Control

11. Unscrew the load valve on the service flowmeter to
the lowest setting.
12. Start the engine and set engine speed to 2000 RPM.
13. Increase the load on the service flowmeter until the
flow has dropped to 19 l/min (5 US gpm) or less.
14. Read the pressure on the 5000 psi gauge. This is the
torque compensator margin setting. The acceptable
range for all models is 17 - 19 bar (246 - 275 psi).
15. If the pressure must be adjusted, loosen the lock-
nut on the torque control compensator and adjust the
set screw. Tightening the set screw will increase the
pressure setting and loosening the set screw will de-
crease the pressure setting.
17. After the torque control compensator pressure has
been adjusted correctly, remove the hose that con-
nects the compensator to the hydraulic reservoir. Re-
install the cap on the hydraulic reservoir.
18. Remove the cap that was installed at the torque con-
trol variable relief valve.
19. Reinstall the torque control supply tube.
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NOTICE: Remove the 34.5 bar (500 psi) gauge from the diagnostic fitting. The system will be tested at pressures
greater than 34.5 bar (500 psi) and the will be damaged or destroyed if it is not removed for the remainder of the test.
NOTICE: The hydraulic oil temperature should never be allowed to rise above 80 °C (175 °F). If at any time the oil rises
above this temperature, set the load valve in the service flowmeter to its lowest setting and allow the oil to circulate
and cool before continuing this test. This temperature should be checked every five minutes while preforming this
test.
21. Increase the load on the service flowmeter to read
165 bar (2400 psi) on the left gauge of the flowme-
ter. Record the flow rate on the flowmeter. For the
580SN and 580SN WT. the acceptable range is 125
- 128 l/min (33 - 33.7 US gpm). For the 590SN, the
acceptable range is 130 - 140 l/min (34.4 - 37 US
gpm).
22. If the correct flow rate is not shown on the flowmeter,
the torque control variable relief valve will need to be
adjusted.
1. Remove the plastic cap from the torque control
variable relief.
2. Ensure the SMALL lock nut is tight on the relief.
3. Loosen the LARGE locknut on the variable re-
lief.
4. Tighten the set screw to increase the flow on
the flowmeter. Loosen the setscrew to de-
crease the flow on the flowmeter.
5. Retighten the LARGE locknut on the variable
relief.
6. Check the flow on the flowmeter. Note that
adjusting the torque control variable relief may
slightly change the pressure at the service
flowmeter. Be sure to reset the load to 165.5
bar (2400 psi) before checking the flow.
23. Check the temperature of the hydraulic oil in the
reservoir. The oil should never be allowed to rise
above 80 °C (175 °F). If at any time the oil rises
above this temperature, set the load valve in the ser-
vice flowmeter to its lowest setting and allow the oil
to circulate and cool before continuing this test. This
temperature should be checked every five minutes
while preforming this test.
24. Once the flow at the 165.5 bar (2400 psi) load level
is checked, the flow must be set at a higher level.
Increase the load at the service flowmeter to 221 bar
(3200 psi). The flow on the flowmeter should be 95
- 105 l/min (25 - 28 US gpm) for the 580SN and
580SN WT. The flowmeter should read 95 - 105 l/min
(25 - 28 US gpm) for the 590SN.
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25. If the correct value is not shown on the flowmeter for

the higher load case, the torque control variable relief
valve will need to be adjusted.
variable relief.
2. Ensure the LARGE locknut is tight on the relief.
3. Loosen the SMALL locknut on the variable re-
lief.
the flowmeter. Loosen the set screw to de-
crease the flow on the flowmeter,
5. Tighten the SMALL locknut on the variable re-
lief.
flowmeter. Be sure to reset the load to 165.5
bar (2400 psi) before checking the flow.
NOTE: Note that adjusting the set screw on the variable relief with either the large or small locknut will slightly change
the setting of the other. Repeat steps 21 to 25 making slight adjustments until the flow is correct at each load case.
26. Repeat the set up steps in reverse order to return the
machine to working condition.
NOTE: Any steps related to the torque control supply tube may be eliminated since the tube was reinstalled at an
earlier step.
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Hydraulic systems - Adjust Torque Control Adjustment, 580SN,

580SN WT and 590SN machines with Pilot Controls
For this test the machine will see pressure of at least 221
bar (3200 psi). A 75 US gpm flowmeter ( CAS10280)
will be used. If the flowmeter is equipped with pipe thread
connections, these fittings will have to be removed and re-
placed with ORFS connections (p/n 87303844). A hose
with a minimum 275 bar (4000 psi) working pressure must
be used. It is recommended that the hoses be made 8 ft
to 12 ft long with #16 female ORFS (1 7/16-12) ends.
1. Remove the tee from the pressure outlet at the rear
of the pump and install a plug ( 9847694) in the open
end of the tee and tighten.
2. Attach one end of a test hose to the adapter fitting at
the pressure outlet of the pump. Connect the other
end of the hose to the inlet port of the test flowmeter.
3. Remove the #16 ORB internal hex plug from the rear
face of the backhoe valve.
4. Install a long #16 ORB to #16 ORFS adapter fitting (
87326799) in the open port of the backhoe valve.
5. Connect the end of the second test hose at the
adapter fitting on the backhoe valve. The opposite
end of the hose must be connected to the outlet of
the service flowmeter.
6. Remove the plug from the pressure gauge port at the
top rear of the pump.
7. Install a tee 84151565 in the gauge port at the top of
the pump.
8. Remove the hose that connects the load sense com-
pensator to the power lift valve. Cap the open con-
nection at the power lift valve.
9. Connect a hose from the tee at the gauge port of the
pump to the open port at the LS compensator. The
hose needs to have #6 ORFS female ends and be
rated to 275 bar (4000 psi).
10. Connect a diagnostic fitting 190119A1 at the avail-
able port on the gauge port tee.
machine, start the engine and set the throttle to 2000
RPM. Adjust the load valve at the service flowmeter
to 172 - 207 bar (2500 - 3000 psi). Allow the ma-
chine to run in this condition until the temperature is
reached.
diagnostic fitting installed at the tee in the gauge port
of the pump.
14. Remove the torque control supply tube from the
pump.
15. Cap the open adapter fitting 574342 at the variable
relief valve.
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16. Connect a hose from the open port at the torque con-
trol compensator and run into the fill neck of the hy-
draulic reservoir.
RCPH10TLB013FAM 1
(1) Torque Control Variable Relief

(2) Torque Control Supply Tube
(3) Gauge Port
(4) Mode Selection Solenoid
(5) Load Sense Compensator (580SN with Power Lift, 580SN WT, 590SN)
(6) Torque Control Compensator
(7) Load Sense Port
Checking Torque Control

17. Unscrew the load valve on the service flowmeter to
the lowest setting.
19. Increase the load on the service flowmeter until the
flow has dropped to 19 l/min (5 US gpm) or less.
20. Read the pressure on the 34.5 bar (500 psi). This is
the torque compensator margin setting. The accept-
able range for all models is 17 - 19 bar (246.5 - 275.5
psi).
21. If the pressure must be adjusted, loosen the lock-
nut on the torque control compensator and adjust the
set screw. Tightening the set screw will increase the
pressure setting and loosening the set screw will de-
crease the pressure setting.
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23. After the torque control compensator pressure has

been adjusted correctly, remove the hose that con-
nects the compensator to the hydraulic reservoir. Re-
install the cap on the hydraulic reservoir.
24. Remove the cap that was installed at the torque con-
trol variable relief valve.
25. Reinstall the torque control supply tube.
NOTICE: Remove the 500 psi gauge from the diagnostic fitting. The system will be tested at pressures greater than
500 psi and the will be damaged or destroyed if it is not removed for the remainder of the test.
NOTICE: The oil should never be allowed to rise above 80 °C (175 °F). If at any time the oil rises above this tem-
perature, set the load valve in the service flowmeter to its lowest setting and allow the oil to circulate and cool before
continuing this test. This temperature should be checked every five minutes while preforming this test.
27. Increase the load on the service flowmeter to read
165.5 bar (2400 psi) on the left gauge of the flow
meter. Record the flow rate on the flowmeter. For
the 580SN and 580SN WT. the acceptable range is
125 - 135 l/min (33 - 35.6 US gpm). For the 590SN,
the acceptable range is 130 - 140 l/min (34.4 - 37
US gpm).
28. If the correct flow rate is not shown on the flowmeter,
the torque control variable relief valve will need to be
adjusted.
variable relief.
2. Ensure the SMALL lock nut is tight on the relief.
3. Loosen the LARGE locknut on the variable re-
lief.
the flowmeter. Loosen the setscrew to de-
crease the flow on the flowmeter.
5. Retighten the LARGE locknut on the variable
relief.
flowmeter. Be sure to reset the load to 2400
psi before checking the flow.
29. Check the temperature of the hydraulic oil in the
reservoir. The oil should never be allowed to rise
above 80 °C (175 °F). If at any time the oil rises
above this temperature, set the load valve in the ser-
vice flowmeter to its lowest setting and allow the oil
to circulate and cool before continuing this test. This
temperature should be checked every five minutes
while preforming this test.
30. Once the flow at the 2400 psi load level is checked,
the flow must be set at a higher level. Increase the
load at the service flowmeter to 220 bar (3200 psi).
The flow on the flowmeter should be 90 - 100 l/min
(23.8 - 26.4 US gpm) for the 580SN and 580SN WT.
The flowmeter should read 95 - 105 l/min (25 - 27.7
US gpm) for the 590SN.
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31. If the correct value is not shown on the flowmeter for

the higher load case, the torque control variable relief
valve will need to be adjusted.
variable relief.
2. Ensure the LARGE locknut is tight on the relief.
3. Loosen the SMALL locknut on the variable re-
lief.
the flowmeter. Loosen the set screw ti de-
crease the flow on the flowmeter,
5. Tighten the SMALL locknut on the variable re-
lief.
flowmeter. Be sure to reset the load to 2400
psi before checking the flow.
NOTE: Note that adjusting the set screw on the variable relief with either the large or small locknut will slightly change
the setting of the other. Repeat steps 21 to 26 making slight adjustments until the flow is correct at each load case.
32. Repeat the set up steps in reverse order to return the
machine to working condition.
NOTE: Any steps related to the torque control supply tube may be eliminated since the tube was reinstalled at an
earlier step.
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Hydraulic systems - Testing - Problem in a loader circuit

Check the machine for missing or Yes, check the O-ring on the end of No, check the operation of the spool
damaged parts. If equipped with ride the circuit relieve valve or plug. in both directions. Is the spool oper-
control, make sure the ride control ation correct? If no, remove and in-
button is in the OFF position. spect the spool and loader valve for
Check damage. Repair or replace the spool
Check the operation of the problem or valve, as necessary.
circuit, Do the cylinder(s) move in
both directions.
Is the circuit relief valve or plug Yes, check the setting of the circuit No, replace the O-ring.
O-ring within acceptable limits? relief valve, if used, for the problem
circuit. Is the setting correct?
Is the circuit relief valve setting cor- Yes, check the cylinder piston pack- No, adjust circuit reliefs.
rect? ing. Is the cylinder piston packing
acceptable?
Is the cylinder piston packing accept- Yes, the control valve has internal No, replace or repair the cylinder, as
able? wear or damage. Repair or replace necessary.
the individual section or control valve
as necessary.
Hydraulic systems - Testing - Problem in the 4x1 Clam Circuit

Check for power at controller, Is Yes, disconnect solenoids, activate No, check fuse, check wring to con-
power present at controller? circuit. troller.
Is power present at solenoids? Yes, take an Ohm reading on the No, check wiring to solenoids.
solenoids, a reading of 5.4 Ohms at
20 °C (68.0 °F) should be obtained.
Are the Ohm readings correct? Yes, check pilot pressure at pilot No, replace solenoids.
manifold, a reading of 24 - 34.5 bar
(348.0 - 500 psi)should be obtained.
Is the pilot pressure correct? Yes, Does the accumulator hold a No, replace pressure reducing
charge. To check the accumulator, catridge.
open the clam so the weight of the
clam is on the cylinders, raise the
loader and hold under pressure for
30 seconds. Stop the engine, turn
the ignition switch to accessory, acti-
vate the clam switch to the close po-
sition.
Does the clam drop? Yes, check for operation of spool in No, replace the accumulator.
both directions.
Is the spool operation correct? Yes, check whether the cylinder No, remove and inspect the spool
packing is within acceptable limits. and loader valve for damage. Repair
or replace the spool or valve as nec-
essary.
Is the cylinder piston packing within Yes, troubleshooting complete. No, repair the cylinder, as necessary.
acceptable limits?
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Hydraulic systems - Testing 580N Machines only

Check the machine for missing or Yes, does the pilot accumulator hold No, replace the pressure reducing
damaged parts. If equipped with ride a charge. To check the accumula- cartridge. If still no, remove and in-
control, make sure the ride control tor, extend the dipper out from the spect the check valve orifice.
button is in the OFF position. machine so the weight of the dip-
Check per is on the cylinder, curl the bucket
Operations slow or not working cor- and hold under pressure for 30 sec-
rectly. Check the pilot pressure at pi- onds. Stop the engine, turn the igni-
lot control manifold. Reading should tion switch to accessory, activate the
be 24 - 34.5 bar (348.0 - 500.3 psi) pilot controls, pull the dipper control
Is pilot pressure correct? lever.
Does the dipper drop? Yes, is the minimum displacement No, replace the accumulator.
bypass valve stuck open?
Does the valve move freely? Yes, load sensing relief not set cor- No, remove and examine for con-
rectly or contaminated. Take pres- tamination jamming the valve open.
sure reading at "M" port on backhoe If contaminated, replace valve.
valve by operating a stabilizer over Clean hydraulics, refer to section
relief. Hydraulic systems - Cleaning
(35.000)
Is the pressure setting correct, 207 - Yes, check the setting of the circuit No, adjust the LS relief setting. If re-
214 bar (3001.5 - 3103.0 psi) relief valve, if used, for the problem lief cannot be achieved, replace the
circuit. LS relief valve.
Is the circuit relief valve setting cor- Yes, low pilot pressure at backhoe No, replace of adjust the circuit relief
rect? valve pilot port for the specific func- valve.
tion. Reading should be 24 - 34.5
bar (348.0 - 500.3 psi)
Is the pilot pressure correct? Yes, remove the end cap of the pilot No, Is the function controlled by the
spool chamber and check that the hydraulic joystick or by an electrically
spool moves freely. controlled solenoid? Hydraulic: If
pressure is less than 24 bar (348.0
psi) and pilot pressure at the point
manifold pressure is OK, replace the
joystick control valve. If the prob-
lem is not fixed replace the pres-
sure reduction manifold. Electrical:
Check the electronic controller for er-
ror codes, repair faults. If the prob-
lem is not fixed replace the pressure
reduction manifold.
Does the spool move freely? Yes, check the boom section regen- No, replace the valve section. See
erative spool. To check extend the section Stacked control valves
boom out behind the machine about Loader bucket - Remove - Me-
3 foot from the ground, with the en- chanical linkage backhoe ma-
gine at high idle raise the boom. chines only (35.359)
Does the boom go down slightly be- Yes, replace the boom section in the No, go to next test.
fore raising? backhoe valve.
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Is engine load excessive when a hy- Yes, adjust the pump compensator No, check the cylinder piston pack-
draulic function is stalled? (Pump to 20 bar (290 psi)and minimum dis- ing.
does not destroke). placement bypass to 26 bar (377.0
psi). NOTE: Oil that is cold, below
4 °C (39.2 °F) will have the same af-
fect, heat they hydraulic oil accord-
ing to instructions in the operator's
manual.
Is the cylinder piston packing good? No, NOTE: Boom cylinder only. A Yes, troubleshooting complete.
cushion relief valve is installed in the
piston. The problem in the boom cir-
cuit can be the cushion relief valve
instead of the cylinder piston pack-
ing. Repair the cylinder, as neces-
sary.
Hydraulic systems - Testing - Single function will not work

independently from other functions
Sectional pressure check Sectional pressure compensator Replace sectional compensator or
plugged or jammed. valve section. See section Stacked
control valves Loader bucket - Re-
move - Mechanical linkage back-
hoe machines only (35.359)
Hydraulic systems - Testing

Intermittent stabilizer operation. Is Yes, check the connectors at the No, make sure the electronic con-
operator waiting 1 to 2 seconds be- proportional control solenoids and trols are in the neutral position when
fore operating the stabilizers after switches for good contacts. placing the pilot system switch to the
power up the system? "ON" position.
Are the contacts good? Yes, check proportional valves for No, repair connectors.
sticking. Remove the solenoid,
attach a 12V system to the sole-
noid connectors. Connect and dis-
connect power while watching for
plunger movement.
Does the plunger move? Yes, troubleshooting complete. No, replace the solenoid. NOTE:
Check for operation within the 6
small holes in the stem. There is only
a slight movement of the plunger.
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Hydraulic systems - Testing

Examine swivel mechanism. Yes, See next test. No, if shafts are bent or knuckles are
Check distorted, replace swivel assembly.
Are the swivel shafts or the knuckle
joints undamaged?
Do electrically controlled compo- Yes, go to next test. No, if solenoids have power but are
nent operations stop after release not returning to neutral, replace con-
of switch, stabilizer, extend-a-ahoe, trol solenoids, if solenoids do not
auxiliary hydraulics? have power, replace the switch.
Pull up the boot on the handle, ex- Yes, go to next test. No, disassemble pilot control han-
amine valves for free movement. dles, See section Remote control
Check with machine off then check valve - Remove - Pilot controls
with machine on and pilot controls backhoe valve (35.204) and check
energized. Do spool return to neu- for defects or contamination. If con-
tral freely. taminated, clean, reassemble and
test, if defects found, replace handle
assembly.
Connect a tee into the pilot circuit Yes, go to next test. No, if pressure does not drop to 0 -
that is not returning to neutral, attach 0.4 bar (0.000 - 5.8 psi)replace the
a 70 bar (1015.0 psi) gauge. Full control handle.
stroke the function and record pres-
sure, release the function. Does the
pressure drop instantaneously.
Remove pilot spool end cap. Does Yes, go to next test. No, remove spool and check for con-
the spool move freely? tamination, clean the components,
reassemble and test. If defects
are found replace defective compo-
nents.
Remove pilot spool end cap. Are Yes, troubleshooting complete. No, if defects are found replace de-
spool centering rings free of defects? fective components.
Hydraulic systems - Testing - Noise from the backhoe hydraulic

system
Does the system operate normally Yes, troubleshooting complete. No, air in the pilot system or system
without noise. pressure is low. 1. Crack open the
pilot lines on the pilot end caps at the
backhoe valve, operate each func-
tion until no air spits or bubbles out of
the lines. 2. Start the machine and
operate the backhoe, fully stroking
each function back and forth. Con-
tinuously operate the systems until
the oil is at operating temperature. If
noise persists, shut down and allow
to cool and repeat the procedure.
Low pilot pressure will not fully shift Yes, troubleshooting complete. No, replace the pressure reducing
the spool. Reading should be 24 - cartridge.
34.5 bar (348.0 - 500.3 psi). Is the
pilot pressure correct?
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Hydraulic systems - Testing - All pilot controls stop working

Yes, check the relay for proper con-
Check the fuse. Is the fuse service- No, replace fuse.
able? nection.
Is the relay properly connected? Yes, check enable switch for proper No, reconnect relay.
connection.
Is the enable switch properly con- Yes, troubleshooting complete. No, reconnect enable switch.
nected?
Hydraulic systems - Testing - Pilot pattern change does not function

NOTE: Overtorquing will cause the solenoid to bind and stick.
NOTE: Pattern change problems will only affect boom and dipper functions.
Change the switch from #1 setting to Yes, disconnect the pattern changeNo, check for power to the switch, if
#2 setting. Does pattern change light solenoids and check for power. power is present change the switch,
illuminate? if no power see electrical trou-
bleshooting.
Is there power at both of the pattern Yes, remove and check O-rings on No, check wiring and connectors.
change solenoids? solenoids.
Are O-rings serviceable? Yes, swap the solenoids and check No, replace O-rings.
operation.
Did bad operation reverse? Yes, replace the solenoids. Check the torque on the solenoid coil
mounting nuts, torque should be 1.7
- 2.2 N·m (15.0 - 19.5 lb in)
Hydraulic systems - Testing - Fault codes for pilot controller

NOTE: Pilot controller is located above and to the left hand side of the rear axle, codes will flash on 0.25 seconds, off
0.25 seconds and will pause for 2 seconds between codes.
Fault code 1: Stabilizer, extend-a- No, troubleshooting complete. Yes, test solenoids, 5.5 Ohms at 20
hoe or auxiliary control shorted to °C (68 °F), replace as needed.
ground or open circuit. Check wiring
from stabilizer, extend-a-hoe or aux-
iliary control to module, is there still
a problem?
Is there still a problem? No, troubleshooting complete. Yes, replace control module.
Fault code2: Stabilizer, ex- No, troubleshooting complete. Yes, check wiring from stabilizer,
tend-a-hoe or auxiliary hydraulics extend-a-hoe or auxiliary control to
control shorted to Vbat. module.
Is there still a problem? No, troubleshooting complete. Replace control module.
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Fault code 3: Interlock for stabilizer, No, troubleshooting complete. Yes, check that all function switches
extend-a-hoe or auxiliary hydraulics are in the off position or are not de-
controls. pressed, turn the pilot power off and
back on.
Is there still a problem? No, troubleshooting complete. Yes, test, if problem persists, replace
control module.
Fault code4: Driver fault. Check No, troubleshooting complete. Yes, test solenoids, 5.5 Ohms at 20
wiring from stabilizer, extend-a-hoe °C (68.0 °F), replace as needed.
or auxiliary control to module, is
there still a problem?
Is there still a problem? No, troubleshooting complete. Replace control module.
Fault light on with no blink. Replace No, troubleshooting complete. Yes, call technical support.
control module, is there still a prob-
lem?
Fault light off. No power to module No, troubleshooting complete. Yes, replace control module.
or faulty control module. Check fuse
and pilot control relay, is there still a
problem?
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Index

Hydraulic systems - Adjust Torque Control Adjustment, 580SN, 580SN WT and 590SN machines with Mechanical
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Hydraulic systems - Adjust Torque Control Adjustment, 580SN, 580SN WT and 590SN machines with Pilot Controls
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Hydraulic systems - Assemble - Regulated manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Hydraulic systems - Check - Flowmeter Check Sheet, 580N Mechanically Controlled machines . . . . . . . . . . . . . 83
Hydraulic systems - Check - Flowmeter Check Sheet, 580N Pilot machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Hydraulic systems - Check Flowmeter Check Sheet, All 580SN, 580SN WT and 590SN machines . . . . . . . . . . . 99
Hydraulic systems - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Hydraulic systems - Disassemble - Regulated manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Hydraulic systems - Dynamic description - Closed center hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hydraulic systems - Dynamic description - Hydraulic system identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Hydraulic systems - Dynamic description - Open center hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Hydraulic systems - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Hydraulic systems - Exploded view - Hydraulic gear pump seal, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Hydraulic systems - Exploded view - Hydraulic gear pump, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Hydraulic systems - Exploded view - Regulated manifold, Pilot Controls only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Hydraulic systems - Exploded view 580N Pilot Machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Hydraulic systems - Exploded view 580SN, 580SN WT and 590SN machines with pilot controls . . . . . . . . . . . . . 49
Hydraulic systems - Exploded view Hydraulic Pump 580SN, 580SN WT and 590SN . . . . . . . . . . . . . . . . . . . . . . . 44
Hydraulic systems - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic systems - Hydraulic schema Regulated manifold hydraulic schematic, Pilot Controls Only . . . . . . . . . 46
Hydraulic systems - Prepare - Machine Preparation, 580N Mechanically Controlled machines . . . . . . . . . . . . . . . 75
Hydraulic systems - Prepare - Machine Preparation, 580N Pilot machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Hydraulic systems - Prepare Machine Preparation, All 580SN, 580SN WT and 590SN machines . . . . . . . . . . . . 86
Hydraulic systems - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic systems - Test Pressure Test, 580N Mechanically Controlled machines . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Hydraulic systems - Test Pressure Test, 580N Pilot machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Hydraulic systems - Test Pressure Test, All 580SN, 580SN WT and 590SN machines . . . . . . . . . . . . . . . . . . . . . . 88
Hydraulic systems - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Hydraulic systems - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Hydraulic systems - Testing - All pilot controls stop working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Hydraulic systems - Testing - Fault codes for pilot controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Hydraulic systems - Testing - Noise from the backhoe hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Hydraulic systems - Testing - Pilot pattern change does not function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
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Hydraulic systems - Testing - Problem in a loader circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Hydraulic systems - Testing - Problem in the 4x1 Clam Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Hydraulic systems - Testing - Single function will not work independently from other functions . . . . . . . . . . . . . . 112
Hydraulic systems - Testing 580N Machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
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Pump control valves - 102
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Pump control valves

Drawing Backhoe Control Valve, 8 Spool, Extendahoe with Pilot Controls, 580SN, 580SN WT and 590SN
machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drawing Backhoe Control Valve, 8 Spool, Extendahoe with Pilot Controls, 580N machines . . . . . . . . . . . 4
Drawing Loader Valve, 2 Spool for 580N with mechanical controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drawing Loader Valve, 2 Spool for 580N with pilot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drawing Loader Valve, 3 Spool for 580N with mechanical backhoe controls . . . . . . . . . . . . . . . . . . . . . . . . 7
Drawing Loader Valve, 3 Spool for 580N with pilot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Drawing Loader valve, 3 Spool for 580SN, 580SN WT and 590SN with mechanical backhoe controls . 9
Drawing Loader Valve, 3 Spool for 580SN, 580SN WT and 590SN with Pilot Controls . . . . . . . . . . . . . . 10
Drawing Backhoe Valve, 8 Spool foot swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Sectional view Stabilizer Section, 580N, 580SN, 580SN WT and 590SN machines with Pilot Controls 13
Sectional view Boom, Dipper, Bucket, Extendahoe Sections, 580N, 580SN, 580SN WT and 590SN ma-
chines with Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Exploded view - Ride control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Exploded view - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SERVICE
Pump control valves

Cleaning 580N Pilot machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cleaning - Swing, Bi-Dir Aux and Stabilizer sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cleaning 580SN, 580SN WT and 590SN machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Disassemble - Ride control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assemble - Ride control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disassemble - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inspect - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Assemble - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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Hydraulic systems - Pump control valves
Pump control valves - Drawing Backhoe Control Valve, 8 Spool,

Extendahoe with Pilot Controls, 580SN, 580SN WT and 590SN
machines
RCPH10TLB013GAM 1
1. Inlet 4. Left Stabilizer 7. Bucket

2. Swing 5. Right Stabilizer 8. Extendahoe
3. Boom 6. Dipper 9. Bi-Dir Aux
10 Outlet
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Pump control valves - Drawing Backhoe Control Valve, 8 Spool,

Extendahoe with Pilot Controls, 580N machines
RCPH11TLB004GAM 1
(1) Inlet (7) Bucket

(2) Swing (8) Extendahoe
(3) Boom (9) B-Dir Aux
(4) Left Stabilizer (10) Outlet
(5) Right Stabilizer (11) LS Relief
(6) Dipper (12) LS Drain
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Pump control valves - Drawing Loader Valve, 2 Spool for 580N with
mechanical controls
RCPH11TLB006FAM 1
(1) Power Beyond port (4) Gage Port

(2) Inlet port (5) Lift section
(3) Main Relief (6) Bucket section
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pilot controls
RCPH11TLB001FAL 1
(1) Power Beyond port (4) Lift section

(2) Inlet port (5) Bucket section
(3) Gage Port
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mechanical backhoe controls
RCPH11TLB007FAM 1
(1) Power Beyond port (5) Lift section

(3) Main Relief (7) Clam section
(4) LS Port (8) Outlet
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pilot controls
RCPH11TLB002FAL 1
(1) Power Beyond port (5) Bucket section

(2) Inlet port (6) Clam section
(3) LS Port (7) Outlet
(4) Lift section
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Pump control valves - Drawing Loader valve, 3 Spool for 580SN,

580SN WT and 590SN with mechanical backhoe controls
RCPH11TLB005GAM 1

(2) Spike clipper (Internal component) (8) Clam section
(3) Priority spool (Internal component) (9) Power Beyond
(4) Steering pressure port (10) Outlet
(5) LS port (11) Main Relief Valve
(6) Lift section
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Pump control valves - Drawing Loader Valve, 3 Spool for 580SN,

580SN WT and 590SN with Pilot Controls
RCPH11TLB003GAM 1
(1) Clam Section (6) Inlet Section

(2) Bucket Section (7) Steering Pressure Port
(3) Lift Section (8) Steering Load Sense Port (Bottom Face of
Inlet — Not Shown)
(4) Main LS Port (9) Tank
(5) Pressure Inlet
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Pump control valves - Drawing Backhoe Valve, 8 Spool foot swing
RCPH11TLB001HAM 1
(1) Inlet port (7) Stabilizer

(2) Outlet port (8) Stabilizer
(3) Auxiliary (9) Boom
(4) Extendahoe (10) Swing
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(5) Bucket (11) Boom low leak check

(6) Dipper (12) Bi-Aux lock solenoid
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Pump control valves - Sectional view Stabilizer Section, 580N,

580SN, 580SN WT and 590SN machines with Pilot Controls
RCPH10TLB062FAM 1
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Pump control valves - Sectional view Boom, Dipper, Bucket,

Extendahoe Sections, 580N, 580SN, 580SN WT and 590SN
machines with Pilot Controls
RCPH10TLB062FAM 1
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Pump control valves - Exploded view - Ride control solenoid valve
RCPH10TLB008CAM 1
(1) Ring Nut (3) Cartridge

(2) Coil (4) Control Block
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Pump control valves - Exploded view - Boom lock solenoid valve
RCPH10TLB002HAN 1
1. Relief valve body 5. Poppet 9. Piston 13. O-ring

2. Relief valve seat 6. O-ring 10. O-ring 14. Solenoid body
3. O-ring 7. Outer spring 11. Screw 15. Solenoid
4. Backup ring 8. Inner spring 12. Nut
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Pump control valves - Cleaning 580N Pilot machines only

1. Remove valve from machine, see Remote control
valve - Remove (35.204)
2. Clean the valve.
3. Loosen the plug.
NOTE: During assembly torque to 90 - 110 N·m (66 - 81 lb
ft).
RCPH10TLB392ABL 1
4. Remove the plug.
RCPH10TLB393ABL 2
RCPH10TLB394ABL 3
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RCPH10TLB395ABL 4
7. Loosen the load sense relief valve.

ft).
RCPH10TLB396ABL 5
8. Remove the load sense relief valve.
RCPH10TLB397ABL 6
9. Loosen load sense drain orifice.

ft).
RCPH10TLB398ABL 7
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10. Remove the load sense drain orifice.
RCPH10TLB399ABL 8
11. Number the sections for correct assembly.
RCPH10TLB400ABL 9
12. Remove the nuts securing the sections.

NOTE: During assembly use new O-rings in all sections
and torque nuts to 42 N·m +/- 4.2 (31 lb ft +/- 3).
RCPH10TLB401ABL 10
13. Remove the end cover.
RCPH10TLB402ABL 11
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14. Continue to separate the working sections from inlet

section.
RCPH10TLB403ABL 12
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Pump control valves - Cleaning - Swing, Bi-Dir Aux and Stabilizer

sections
For Stabilizer Sections, begin at step 8.
1. Unscrew the check valve plug.
RCPH10TLB404ABL 1
2. Remove the check valve. Clean and inspect check

valve, replace as an assembly as needed.
NOTE: During assembly use new O-ring and torque to 30
N·m +/- 3 (22 lb ft +/- 2).
RCPH10TLB405ABL 2
3. Repeat steps 1 and 2 for the other check valve.

4. Remove the cap from the relief valve.
RCPH10TLB406ABL 3
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5. Loosen the relief valve.

ft).
RCPH10TLB407ABL 4
6. Remove the relief valve from the section.
RCPH10TLB408ABL 5
7. Repeat steps 4 through 6 and remove the other pres-

sure relief valve.
8. Loosen and remove the end cap mounting screws.
NOTE: During assembly torque to 9 - 11 N·m (7 - 8 lb ft).
RCPH10TLB409ABL 6
9. Remove the end cap.
RCPH10TLB410ABL 7
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RCPH10TLB411ABL 8
11. Remove the spool guide.
RCPH10TLB412ABL 9
12. Repeat steps 8 through 11 and remove the other end

cap.
13. Remove the spool from the section.
NOTICE: Record spool grove orientation in relation to the
A or B ports. Labels A and B are cast into the valve section.
RCPH10TLB413ABL 10
14. Unscrew the compensator plug.

NOTE: During assembly use new O-ring and torque to 54
- 66 N·m (40 - 49 lb ft).
RCPH10TLB414ABL 11
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15. Remove the compensator piston. Clean and inspect

the piston and bore, use new parts as required.
(1) Solid compensator
RCPH10TLB415ABL 12
(2) Dampened compensator (Stabilizer sections use a load

check)
RCPH10TLB416ABL 13
16. Separate and inspect the dampened compensator or

load check.
RCPH10TLB417ABL 14
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Pump control valves - Cleaning 580SN, 580SN WT and 590SN

machines
1. Remove valve from machine, see Remote control
valve - Remove (35.204)
2. Clean the valve.
3. Loosen the plug.
ft).
RCPH10TLB392ABL 1
4. Remove the plug.
RCPH10TLB393ABL 2
RCPH10TLB394ABL 3
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RCPH10TLB395ABL 4
7. Loosen and remove the plug installed in the load

sense relief valve location. .
RCPH10TLB396ABL 5
8. Loosen and remove plug installed in the load sense

drain orifice.
RCPH10TLB398ABL 6
9. Number the sections for correct assembly.
RCPH10TLB400ABL 7
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10. Remove the nuts securing the sections.

NOTE: During assembly use new O-rings in all sections
and torque nuts to 42 N·m +/- 4.2 (31 lb ft +/- 3).
RCPH10TLB401ABL 8
11. Remove the end cover.
RCPH10TLB402ABL 9
12. Continue to separate the working sections from inlet

section.
RCPH10TLB403ABL 10
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Pump control valves - Disassemble - Ride control solenoid valve

1. Remove the ring nut (1) from the solenoid.
2. Remove the coil (2).
3. Remove the cartridge (3) from the ride control valve
block.
4. Remove and discard the O-rings from the cartridge.
RCPH10TLB008CAM 1
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Pump control valves - Assemble - Ride control solenoid valve

1. Install new O-rings on the cartridge (3).
2. Lubricate the O-rings on the cartridge with clean hy-
draulic oil.
3. Install and tighten the cartridge in the ride control
valve block.
4. Install the coil (2).
5. Install and tighten the ring nut (1).
RCPH10TLB008CAM 1
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Pump control valves - Disassemble - Boom lock solenoid valve

1. Fasten the body of the boom lock solenoid valve in a
vise with soft jaws.
2. Loosen and remove the relief valve body (1).
3. Remove the piston (9), outer spring (7), inner spring
(8), poppet (5), relief valve seat (2), backup ring (4),
and O-ring (3) from the solenoid body.
4. Discard the backup ring and the O-ring.
5. Remove and discard O-ring (13) from the relief valve
body.
6. Remove and discard the O-ring (10) from the piston.
7. Remove the and discard O-ring (6) from the poppet.
RCIL10TLB017BAF 1
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Pump control valves - Inspect - Boom lock solenoid valve

Prior operation:
Pump control valves - Disassemble (35.102)
1. Clean the relief body, the piston, the poppet, and the
relief valve seat in cleaning solvent.
2. Inspect all the disassembled parts for damage or
wear.
3. Replace as needed.
4. Inspect the solenoid in the solenoid valve for dam-
age.
5. If damage is found, replace the solenoid. DO NOT
repair the solenoid.
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Pump control valves - Assemble - Boom lock solenoid valve

Prior operation:
Pump control valves - Inspect (35.102)
1. Install a new O-ring (3), a new backup ring (4), the

relief valve seat (2), a new O-ring (6), the poppet (5),
the inner spring (8), the outer spring (7), a new O-ring
(10), and the piston (9) into the solenoid body.
2. Install a new O-ring (13) onto the relief valve body
(1).
3. Install the relief valve body onto the solenoid body.
4. Adjust the pressure setting of the relief valve. Refer
to the instructions provided with the relief valve.
RCIL10TLB017BAF 1
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Index

Pump control valves - Assemble - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Pump control valves - Assemble - Ride control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Pump control valves - Cleaning - Swing, Bi-Dir Aux and Stabilizer sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Pump control valves - Cleaning 580N Pilot machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Pump control valves - Cleaning 580SN, 580SN WT and 590SN machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Pump control valves - Disassemble - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Pump control valves - Disassemble - Ride control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Pump control valves - Drawing Backhoe Control Valve, 8 Spool, Extendahoe with Pilot Controls, 580N machines 4
Pump control valves - Drawing Backhoe Control Valve, 8 Spool, Extendahoe with Pilot Controls, 580SN, 580SN
WT and 590SN machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pump control valves - Drawing Backhoe Valve, 8 Spool foot swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pump control valves - Drawing Loader Valve, 2 Spool for 580N with mechanical controls . . . . . . . . . . . . . . . . . . . . 5
Pump control valves - Drawing Loader Valve, 2 Spool for 580N with pilot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump control valves - Drawing Loader Valve, 3 Spool for 580N with mechanical backhoe controls . . . . . . . . . . . . 7
Pump control valves - Drawing Loader Valve, 3 Spool for 580N with pilot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pump control valves - Drawing Loader Valve, 3 Spool for 580SN, 580SN WT and 590SN with Pilot Controls . . 10
Pump control valves - Drawing Loader valve, 3 Spool for 580SN, 580SN WT and 590SN with mechanical backhoe
controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Pump control valves - Exploded view - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pump control valves - Exploded view - Ride control solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pump control valves - Inspect - Boom lock solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Pump control valves - Sectional view Boom, Dipper, Bucket, Extendahoe Sections, 580N, 580SN, 580SN WT and
590SN machines with Pilot Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pump control valves - Sectional view Stabilizer Section, 580N, 580SN, 580SN WT and 590SN machines with Pilot
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Variable displacement pump - 106
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Variable displacement pump

Sectional view Hydraulic Pump, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sectional view Hydraulic Pump, 580SN, 580SN WT and 590SN with Power Lift . . . . . . . . . . . . . . . . . . . . 4
Drawing - Output Test Hose Connections, 580SN, 580SN WT and 590SN . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drawing Power Lift Valve 580SN, 580SN WT and 590SN machines with Mechanical Controls . . . . . . . . 6
Drawing Power Lift Valve 580SN, 580SN WT and 590SN machines with Pilot Controlled Backhoe . . . . 7
SERVICE

Remove - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove - 580SN, 580SN-WT and 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install - 580SN, 580SN-WT and 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Disassemble - Priority Valve, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Inspect - Priority Valve, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Assemble - Priority Valve, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Prepare Work Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Disassemble - Single Section Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assemble - Single Section Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
580N, 580N NA, 580SN, 580SN WT, 590SN
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSTIC

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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Hydraulic systems - Variable displacement pump
Variable displacement pump - Sectional view Hydraulic Pump,

580N only
RCPH10TLB011FAM 1
1. Inlet 3. CF Port 5. Priority Valve

2. EF Port 4. Load Sensing Port
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Variable displacement pump - Sectional view Hydraulic Pump,

580SN, 580SN WT and 590SN with Power Lift
RCPH10TLB043GAM 1
1. Load Sense Spool 5. Inlet 8. Torque Control Variable Relief

2. Case Drain 1 6. Outlet 9. Case Drain 2
3. Load Sense Port (LS) 7. Gage Port 10. Torque Regulation Selection Solenoid
4. Torque Control Spool
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Variable displacement pump - Drawing - Output Test Hose

Connections, 580SN, 580SN WT and 590SN
RCPH10TLB006GAM 1
1. Load sense hose 2. Return hose from loader valve 3. Pressure to backhoe valve
4. Attenuator hose to hydraulic pump 5. Back pressure check valve 6. To hydraulic filter
7. Attenuator hose 8. Test Adapter
NOTE: Connect flowmeter input hose to attenuator hose.

NOTE: Remove hydraulic tank filler cap and place flowmeter outlet hose (6) below oil level. Ensure hose is secured.
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Variable displacement pump - Drawing Power Lift Valve 580SN,

580SN WT and 590SN machines with Mechanical Controls
Power Lift Valve
RCPH10TLB063FAM 1
(1) Main relief valve (5) Return to tank

(2) Power Lift relief valve (6) Load sense gauge port
(3) Load sense port (Out to pump) (7) Power Lift solenoid
(4) Pressure Inlet (8) Orifice
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Variable displacement pump - Drawing Power Lift Valve 580SN,

580SN WT and 590SN machines with Pilot Controlled Backhoe
Power Lift Valve
RCPH10TLB012FAM 1
1. Low pressure relief valve 6. Filter screen

2. High pressure relief valve 7. Load sense gauge port
3. Load sense port (Out to pump) 8. Power lift solenoid
4.Load sense port (In) 9. Non adjustable LS drain (Pilot Controls Only)
5. Return to tank 10. Orifice
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Variable displacement pump - Remove - 580N only
NOTE: Put identification tags on all disconnected hoses

and wires. Close disconnected hoses and fittings with caps
and plugs.
1. Park the machine on a level surface and apply the
parking brake.
2. Lower the loader bucket to the floor and stop the
engine.
3. Move the loader and backhoe control levers in all
directions to release the pressure from the hydraulic
circuits.
NOTE: For pilot control machines, turn on ignition switch
and pilot control switch, move pilot handles in all directions
several times to release hydraulic and accumulator pres-
sure.
4. Remove the cap from the hydraulic reservoir. This
will reduce the hydraulic oil loss as the hoses and
tubes are removed from the hydraulic pump.
5. Remove the drive shaft from the transmission to the
rear axle.
6. Remove floor mat (if equipped), remove front center
floor plate.
RCPH10TLB428AAF 1
7. Remove the Allen head screw and loosen the hose

clamp on the inlet hose to the pump.
RCPH10TLB320ABL 2
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8. Remove the two lower mounting nuts, (powershift

transmissions), or bolts (manual transmissions).
RCPH10TLB323ABL 3
9. Attach suitable lifting equipment to the pump.

10. Remove the two upper Allen screws from the pump
inlet, disconnect hoses from fittings (2), (3) and (4).
RCPH11TLB006GAM 4
11. Remove the two upper mounting nuts, (powershift

transmissions), or bolts (manual transmissions).
12. Slide the pump to the rear off of the drive splines,
remove the pump from the machine.
RCPH10TLB325ABL 5
Next operation:
Variable displacement pump - Install (35.106)
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Variable displacement pump - Install - 580N only

Prior operation:
Variable displacement pump - Remove (35.106)
1. Use a new O-ring on pump mounting flange, slide the

pump onto the drive splines.
2. Install but do not tighten the two upper mounting nuts
(powershift transmissions) or bolts (manual trans-
missions).
RCPH10TLB325ABL 1
3. Install and tighten the two lower mounting nuts

(powershift transmissions) or bolts (manual trans-
missions). Tighten the upper mounting nuts/bolts.
RCPH10TLB323ABL 2
4. Remove lifting equipment to the pump.

5. Install but do not tighten the two upper Allen screws
in the pump inlet. Connect and tighten hoses to fit-
tings (2), (3) and (4).
RCPH11TLB006GAM 3
6. Ensure O-ring is installed in the suction flange.
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7. Install the Allen screw. Tighten all three Allen screws

with equal pressure. Tighten the hose clamp on the
inlet hose to the pump.
RCPH10TLB320ABL 4
8. Install the drive shaft to the rear axle.

9. Complete the following procedure to fill the hydraulic
pump with oil.
A. Fill the hydraulic reservoir. Verify the oil level in

the hydraulic reservoir is correct.
B. Remove the cap from the hydraulic reservoir.
C. Use a nozzle and shop air to pressurize the
hydraulic reservoir. Wrap a shop cloth around
the end of the hose at the nozzle.
D. Have another person start and run the engine
at low idle while shop air is being applied to the
hydraulic reservoir.
NOTE: 34.5 - 69.0 kPa (5.0 - 10.0 psi) is all that is required
to move the oil. Pressure above 69.0 kPa (10.0 psi) can
damage the hydraulic reservoir.
10. Operate all hydraulic circuits. Stop the engine and
check for leaks. Fill the hydraulic reservoir as re-
quired.
11. Install floor plate, (if equipped) install floor mat.
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Variable displacement pump - Remove - 580SN, 580SN-WT and

590SN

and wires. Seal disconnected hoses and fittings with caps
and plugs.
parking brake.
engine.
3. Move the loader and backhoe control levers in all
directions to release the pressure from the hydraulic
circuits.
NOTE: Turn on ignition switch and pilot control switch.
Move pilot handles in all directions several times to release
hydraulic and accumulator pressure. If equipped with clam
bucket operate clam controls.
tubes are removed from the hydraulic pump.
5. Remove the drive shaft from the transmission to the
rear axle.
6. Remove floor mat (if equipped), remove front center
floor plate.
RCPH10TLB428AAF 1
7. Disconnect electrical connector from solenoid at rear

of pump.
8. Disconnect the electrical connector from the power
lift solenoid (if equipped).
9. Remove the 2 bolts connecting the power lift valve to
its mounting bracket (if equipped).
10. Disconnect the load sense and pressure lines for the
power lift valve at the ends connected to the pump.
Move the power lift valve over to give more working
room.
11. Disconnect the case drain (1) and output hose (2).
RCPH10TLB013FAM 2
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12. Remove the 2 screws holding the suction line and

power lift bracket.
13. Remove the two lower mounting bolts.
14. Attach suitable lifting equipment to the pump.
15. Remove the two upper mounting bolts.
16. Slide the pump to the rear, off of the drive splines.
Remove the pump from the machine.
NOTICE: Do not use either of the thin tubes on the pump to lift, carry or hold the pump. This will damage the tubes.
Next operation:
Variable displacement pump - Install (35.106)
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Variable displacement pump - Install - 580SN, 580SN-WT and 590SN

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Prior operation:
Variable displacement pump - Remove (35.106)
1. Use a new O-ring on the pump mounting flange.

Slide the pump onto the drive splines.
2. Install but do not tighten the two upper mounting
bolts.
3. Install and tighten the two lower mounting bolts.
Tighten the upper mounting nuts/bolts.
4. Remove lifting equipment from the pump.
5. Verify that the suction flange has the O-ring installed.
6. Connect the inlet hose. If equipped with Power Lift,
connect the Power Lift bracket at the same time.
7. Connect the output hose (1) and load sense hose
(2) (if equipped). and Power Lift pressure hose (if
equipped).
RCPH10TLB013FAM 1
8. Reconnect the Power Lift valve to the bracket using

existing hardware.
9. Reconnect all electrical connectors.
10. Use a hand pump filled with MS1209 and connect
it to the quick coupler on the side of the pump, fill
the pump with approximately 1 l (1 US qt) of oil. If
a hand pump is not available, use a funnel with a
flexible neck to pour oil into the open case drain port
on the pump. If using the funnel method, oil must be
added to the pump until it runs out of the open case
drain port.
RCPH10TLB012BAM 2
11. Connect the case drain hose.

12. Install the drive shaft to the rear axle.
13. Fill the hydraulic reservoir. Verify the oil is at the
correct level.
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14. Start the engine at low idle. Verify that the pump
is operating properly and that it is not making any
unusual noises. Shut down the engine if the pump is
making unusual noises, verify that the pump case oil
level is at the proper level. Verify that the pump inlet
hose is not kinked and that it is connect properly.
15. Recheck the hydraulic oil level in the reservoir. Fill if
needed.
16. Connect a quick coupler and hose to the fitting on the
attenuator hose located at the left side of the backhoe
valve.
17. Attached a needle valve to the hose.
18. Start and operate the machine at low idle for a mini-
mum of 5 min . Use an assistant to monitor the hy-
draulic oil level in the reservoir. Stop the machine
and add oil as needed to maintain the oil level in the
sight glass.
NOTE: The system will have noise until all of the air is
purged.
19. Using the needle valve, slowly open and allow oil to
flow from the valve until there are no noticeable air
bubbles in the stream and the stream is a solid color.
20. Close the needle valve, stop the engine, remove the
hose and quick coupler from the attenuator hose.
21. Start the engine and advance the throttle to mid po-
sition.
22. Wait for a minimum of 15 s before cycling hydraulic
circuits.
NOTE: Oil level will drop in the reservoir, refill reservoir as
necessary to maintain oil level in the sight gauge.
23. Cycle any functions that were disconnected or
drained of hydraulic fluid three complete cycles.
Bottom the cylinder out in each cycle.
NOTE: If no function was disconnected, cycle two of the
following for three complete cycles: backhoe dipper, ex-
tend-a-hoe, backhoe bucket, or loader bucket.
24. Stop the engine and check for leaks. Fill the hy-
draulic reservoir as required.
25. Install floor plate, (if equipped) install floor mat.
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Variable displacement pump - Disassemble - Priority Valve, 580N

only
Hydraulic pumps are precision machined components
and must be handled appropriately. Before beginning
any pump disassembly or repair procedures, clean the
work area thoroughly of all contaminates. It is advised
that clean towels, paper towels or cardboard be placed
on the workbench to provide a clean work surface. The
work are should be free of blowing dust, welding sparks
or anything that could contaminate the pump components.
If any pump component must be cleaned, use a clean
solvent from a can such as brake or carburetor cleaner.
Use of typical shop parts washers is not advised due to
containments in the cleaning fluid.
1. Loosen and remove load sensor fitting from hydraulic
pump.
RCPH10TLB341ABL 1
2. Remove the springs from the pump.
RCPH10TLB342ABL 2
3. Use a magnet and pull the spool from the pump.
RCPH10TLB344ABL 3
Next operation:
Variable displacement pump - Inspect (35.106)
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Variable displacement pump - Inspect - Priority Valve, 580N only

Prior operation:
Variable displacement pump - Disassemble (35.106)
1. Inspect the springs for damaged or broken coils,

check spool and bore for scaring. Replace compo-
nents as needed.
RCPH10TLB345ABL 1
Next operation:
Variable displacement pump - Assemble (35.106)
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Variable displacement pump - Assemble - Priority Valve, 580N only

1. Lubricate spool with clean hydraulic oil and carefully
install into bore.
RCPH10TLB343ABL 1
2. Place springs into spool and push spool into pump

body.
RCPH10TLB342ABL 2
3. Tighten the Priority Valve fitting.
RCPH10TLB341ABL 3
Next operation:
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Variable displacement pump - Prepare Work Surface

Hydraulic pumps are precision machined components
and must be handled appropriately. Before beginning
any pump disassembly or repair procedures, clean the
work area thoroughly of all contaminates. It is advised
that clean towels, paper towels or cardboard be placed
on the workbench to provide a clean work surface. The
work are should be free of blowing dust, welding sparks
or anything that could contaminate the pump components.
If any pump component must be cleaned, use a clean
solvent from a can such as brake or carburetor cleaner.
Use of typical shop parts washers is not advised due to
containments in the cleaning fluid.
Next operation:
Pump Disassembly
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Variable displacement pump - Disassemble - Single Section Gear

Pump
Prior operation:
Variable displacement pump - Prepare Work Surface (35.106)
1. Clean the outside of the hydraulic pump. Fasten the

hydraulic pump in a vise with soft jaws. Make align-
ment marks on each section of the hydraulic pump.
RCPH11TLB001BAL 1
2. Loosen and remove the bolts and the flat washers

that fasten the closed end cover.
RCPH11TLB002BAL 2
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3. Remove the closed end cover.
RCPH11TLB003BAL 3
4. Remove the quad ring.
RCPH11TLB004BAL 4
RCPH10TLB349ABL 5
6. Remove the driven and drive gear.
RCPH10TLB350ABL 6
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7. Remove the shaft end gear housing.
RCPH11TLB005BAL 7
8. If the thrust plate stayed with the end housing, re-

move the thrust plate.
9. Remove the quad ring from the bottom of the shaft
end gear housing or shaft end cover.
RCPH11TLB006BAL 8
10. Remove the snap ring from the shaft end cover.
RCPH10TLB363ABL 9
11. Remove the outer seal and carrier from the shaft end
cover.
RCPH10TLB362ABL 10
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12. Remove the inner seal from the shaft end cover.
RCPH10TLB359ABL 11
13. Remove the seals from the thrust plates.
RCPH10TLB364ABL 12
Next operation:
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Variable displacement pump - Inspect

Prior operation:
Discard all seals and quad rings. Clean all parts in cleaning
solvent. Check all machined surfaces for damage or wear.
1. Hold a straightedge across each gear housing and
use a feeler gauge to measure the amount of wear
caused by the gear teeth in the gear pocket. If the
wear in any gear pocket is more than 0.18 mm (0.007
in), use a new gear housing.
RCPH10TLB448ABL 1
2. Inspect the thrust plates for scoring, pitting, or other

damage.
RCPH10TLB450ABL 2
3. Inspect the gears for wear and damage. There must

be no scoring on the gear hubs or on the outside
edges of the gear teeth. There must be no more than
0.05 mm (0.002 in) wear in the seal area of the drive
shaft. There must be no damage to the splines of
the drive shaft or the coupling. If any gear must be
discarded, you must use a new hydraulic pump.
RCPH10TLB449ABL 3
Next operation:
Variable displacement pump - Assemble (35.106)
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Variable displacement pump - Assemble - Single Section Gear

Pump
Prior operation:
1. Install new quad rings in the grooves in the gear

housings. Use petroleum jelly to hold the quad rings
in position.
2. Press the seal, with the metal side up, into the shaft
end cover until the seal is even with the top of the
seal recess.
RCPH10TLB360ABL 1
3. Install a new seal into the carrier, replace O-ring on

carrier.
RCPH10TLB361ABL 2
4. Press the carrier into the end cover until the snap ring
can be installed in the groove.
RCPH10TLB358ABL 3
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RCPH10TLB363ABL 4
6. Install new seals in the thrust plates.
RCPH10TLB365ABL 5
7. Fasten the shaft end cover in a vise with soft jaws.

Install the thrust plate so that the seal is down and
the open ends of the rectangular relief groove on the
face of the thrust plate are toward the outlet side of
the hydraulic pump.
RCPH11TLB007BAL 6
8. Install the shaft end gear housing.
RCPH10TLB370ABL 7
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9. Install the drive and the driven gear.
RCPH11TLB009BAL 8
10. Install the thrust plate so that the seal is up. The seal
must be toward the outlet side of the hydraulic pump.
RCPH11TLB010BAL 9
11. Install the quad ring.
RCPH11TLB011BAL 10
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12. Install the closed end cover.
RCPH11TLB012BAL 11
13. Install the bolts and the flat washers. Tighten the
bolts evenly to a torque of 339 N·m (250 lb ft).
RCPH11TLB013BAL 12
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Variable displacement pump - Assemble

580N, 580N NA, 580SN, 580SN WT, 590SN
1. Insert the piston and shoe assemblies into the re-

tainer plate.
RCPH10CCH700BAO 1
2. Install the pivot ring (1) on the cylinder block assem-

bly.
RCPH10CCH699BAO 2
3. Install the pistons and retaining plate into the cylinder

block.
4. Place the swash plate on the rotation group.
5. Using a press, install the tapered roller bearing cone.
RCPH10CCH702BAO 3
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6. Install the seal on the pump housing.
RCPH10TLB029BAM 4
7. Insert the shaft into the swash plate and rotation

group.
RCPH10TLB030BAM 5
8. Install the swash plate trunnion bearings (1) in the

pump housing.
RCPH10CCH698BAO 6
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9. Insert the shaft assembly into the pump housing.
RCPH10CCH703BAO 7
Measuring the shaft bearing spacer

10. Install the pump housing o-ring.
RCPH10TLB024BAM 8
11. Install the port block o-rings.
RCPH10TLB023BAM 9
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12. Install the port block on the pump housing. Torque

the bolts to 50 - 54 N·m (37 - 40 lb ft).
RCPH10TLB021BAM 10
13. Install a dial indicator, as shown, with the indicator in

contact with the end of the shaft and set at zero.
RCPH10CCH704BAO 11
14. Pry up on the shaft and record the measurement of

the indicator. Be sure the indicator returns to zero
when the shaft moves downwards. If the indicator
does not return to zero, reset the indicator and repeat
the procedure.
RCPH10CCH705BAO 12
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15. Remove the dial indicator and the port block from
the pump housing. Remove the bearing from the
shaft. Select a bearing spacer that is 0.00 to 0.05 mm
(0.000 to 0.002 inch) thicker than the dial indicator
recorded measurement.
RCPH10CCH706BAO 13
16. Install the bearing adjustment shim.
RCPH10CCH697BAO 14
17. Install the tapered roller bearing cone.
RCPH10CCH696BAO 15
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18. Install the control valve follower. Torque the bolt to

15 - 20 N·m (11 - 15 lb ft).
RCPH10TLB027BAM 16
19. Install the control plate.
RCPH10TLB026BAM 17
20. Install the counter piston spring and counter piston.
RCPH10TLB025BAM 18
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21. Install the control piston guide.
RCPH10TLB022BAM 19
22. Install the port block. Torque the bolts to 50 - 54 N·m

(37 - 40 lb ft).
RCPH10TLB021BAM 20
23. Install the control valve. Torque the bolts to 15 - 16

N·m (10 - 12 lb ft).
NOTE: Verify proper placement of o-rings.
RCPH10TLB020BAM 21
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24. Install the flange cover and gasket. Torque the bolts
to 52 - 61 N·m (38 - 45 lb ft).
RCPH10TLB019BAM 22
25. Install the compensator and gasket. Torque the bolts

to 15 - 16 N·m (10 - 12 lb ft).
RCPH10TLB018BAM 23
RCPH10TLB017BAM 24
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27. Install the solenoid line.
RCPH10TLB016BAM 25
28. Install the compensator valve line.
RCPH10TLB015BAM 26
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Variable displacement pump - Disassemble

Prior operation:
Variable displacement pump - Prepare Work Surface (35.106)
1. Remove the torque tubes from the pump.
RCPH10TLB015BAM 1
2. Remove the solenoid retention nut, o-ring and sole-

noid coil from the pump. The solenoid cartridge can
remain installed .
3. Remove the 4 screws holding the pump compen-
sator. Remove the compensator and gasket.
RCPH10TLB018BAM 2
4. Clamp the pump in a vise with the shaft pointing

down. The vise jaws must be on the side of the pump
mounting flange and NOT on the machined surface
of the machined alignment boss.
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5. Remove the 4 large screws that secure the rear cover

on the pump.
RCPH10TLB021BAM 3
6. Remove the rear cover of the pump and valve plate.

Also remove the control pistons and springs.
7. There is one large and four small o-rings that seal
the rear cover of the pump. Remove these and set
aside.
8. Remove the rear bearing and spacer underneath
from the pump shaft.
9. With a helper, remove the pump from the vise.
10. While holding the rotating group into the pump, tilt
the pump and pour the oil from the pump case into a
bucket or drain pan.
11. Set the pump on a workbench with the shaft horizon-
tal and remove the rotating group from the pump. It
is best to reach in past the cylinder and separate the
piston shoes from the swash plate.
12. Remove the two screws holding the torque control
variable relief onto the to of the pump. Remove the
variable relief.
13. Remove the single screw holding the relief valve cam
onto the swash plate. Note the orientation of the
cam, then pull if free of the swash plate. The cam
is pressed onto a pin, so a pair of pliers may be used
to pull the cam loose.
14. Remove the swash plate and shaft from the pump.
15. Remove the swash plate trunnion bearings (1) from
the pump housing.
RCPH10CCH698BAO 4
16. Remove the seal from the pump housing.
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17. Remove the shaft from the swash plate and rotation
group.
18. Using a press, remove the tapered roller bearing
cone.
RCPH10CCH701BAO 5
19. Mark the pistons and retaining plate with their posi-
tion in the cylinder. Remove the pistons and retaining
plate.
20. Remove the pivot ring (1) from the cylinder block as-
sembly.
RCPH10CCH699BAO 6
21. Remove the piston and shoe assemblies from the

retainer plate.
RCPH10CCH700BAO 7
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Variable displacement pump - Testing

Do a pump test. Is the pump good? Yes, do a stall test according to No, Repair or replace the hydraulic
the instructions in Section Engine - pump.
Speeds stall test normal (all mod-
els) (10.001)
Do a stall test, Is there still a prob- No, troubleshooting complete. Yes, See section Hydraulic sys-
lem? tems - Cleaning (35.000). Is the oil
contaminated?
Is the hydraulic oil contaminated? No, check the remaining circuits. Yes, clean or replace the hydraulic
oil. See Section Hydraulic systems
- Cleaning (35.000)
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Index

Variable displacement pump - Assemble - Single Section Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Variable displacement pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
580N, 580N NA, 580SN, 580SN WT, 590SN
Variable displacement pump - Assemble - Priority Valve, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Variable displacement pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Variable displacement pump - Disassemble - Priority Valve, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Variable displacement pump - Disassemble - Single Section Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Variable displacement pump - Drawing - Output Test Hose Connections, 580SN, 580SN WT and 590SN . . . . . . 5
Variable displacement pump - Drawing Power Lift Valve 580SN, 580SN WT and 590SN machines with Mechanical
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Variable displacement pump - Drawing Power Lift Valve 580SN, 580SN WT and 590SN machines with Pilot Con-
trolled Backhoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Variable displacement pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Variable displacement pump - Inspect - Priority Valve, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Variable displacement pump - Install - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Variable displacement pump - Install - 580SN, 580SN-WT and 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Variable displacement pump - Prepare Work Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Variable displacement pump - Remove - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Variable displacement pump - Remove - 580SN, 580SN-WT and 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Variable displacement pump - Sectional view Hydraulic Pump, 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Variable displacement pump - Sectional view Hydraulic Pump, 580SN, 580SN WT and 590SN with Power Lift . 4
Variable displacement pump - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
47365539 08/07/2012
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Remote control valves - 204
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Remote control valve

Drawing 580N Mechanically Controlled Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drawing 580SN, 580SN WT and 590SN Mechanically Controlled Machines . . . . . . . . . . . . . . . . . . . . . . . . 5
Component diagram - Pilot control color codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drawing Remote Clam Valve for 580SN, 580SN WT and 590SN with Pilot Controlled Backhoe . . . . . . . 7
SERVICE
Remote control valve

Remove - Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install - Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove - Loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install - Loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Remove - Clam control pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Install - Clam control pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Remove - Pilot controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install - Pilot controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Remove - Mechanical controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Install - Mechanical controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Check - Pilot control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 262 Remote control valve - Check - Pilot control unit 35.204 / 32
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Hydraulic systems - Remote control valves
Remote control valve - Drawing 580N Mechanically Controlled

Machines
RCPH10TLB039GAM 1
1. Return to reservoir 4. Clam control block 7. Pressure to clam manifold

2. Pressure hose to spool 5. Accumulator
3. Loader valve 6. Pressure hose to spool
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Remote control valve - Drawing 580SN, 580SN WT and 590SN

Mechanically Controlled Machines
RCPH10TLB041GAM 1
1. Return to reservoir 4. Clam control block 7. Pressure to clam manifold

2. Pressure hose to spool 5. Accumulator
3. Loader valve 6. Pressure hose to spool
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Remote control valve - Component diagram - Pilot control color

codes
RCPH10TBL001GAM 1
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Remote control valve - Drawing Remote Clam Valve for 580SN,

580SN WT and 590SN with Pilot Controlled Backhoe
RCPH10TLB040GAM 1
1. Pump pressure hose 4. Accumulator 7. Loader valve

2. Pressure hose to spool 5. Clam control block 8. Return to reservoir
3. Pressure to clam manifold 6. Pressure hose to spool
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Remote control valve - Remove - Remote control valves

1. Park the machine on a level surface and lower the
bucket to the floor. Stop the engine and apply the
parking brake.
NOTICE: Turn on the ignition switch and the pilot control
switch. Move the backhoe control lever back and forth sev-
eral times to release any hydraulic pressure in the pilot con-
trol circuit.
2. Place the pilot control switch and the ignition switch
in the OFF position.
3. Remove the wrist rest, pull the rubber boot up and
remove the two mounting screws and the retaining
plate.
RCPH10TLB334ABL 1
4. On the right tower (facing rear of machine) remove

the tilt levers.
RCPH10TLB335ABL 2
5. Remove the tilt adjusting knob from rear of tower.
RCPH10TLB336ABL 3
6. Remove the rear floor mat (if equipped) and floor

boards.
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7. Disconnect the electrical connector for the tower, re-

move the boot from the tower.
RCPH10TLB337ABL 4
8. Remove the heat shield from inside of the control

tower.
9. Remove the control mounting bolts, pivot adjusting
knob and pivot bolt from the tower.
RCPH10TLB338ABL 5
10. Disconnect electrical connector from control handle,

remove the upper housing for the tower.
RCPH10TLB332ABL 6
11. Check to ensure all hoses have the proper plastic

tie markers, see illustration Remote control valve
- Component diagram (35.204), prior to removal.
Disconnect one at a time from the remote control
valve. Install plugs in the hoses and caps on the
fittings.
12. Remove the remote control valve from the control
tower.
RCPH10TLB333ABL 7
Next operation:
Remote control valve - Install (35.204)
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Remote control valve - Install - Remote control valves

Prior operation:
Remote control valve - Remove (35.204)
1. Install new O-rings on the adapters for the remote

control valve.
2. Remove the plugs from the hoses. Remove the caps
from the fittings. Connect the hydraulic hoses to the
fittings according to the identification tags.
3. Connect the electrical connectors for the remote con-
trol valve.
4. Place the upper housing around the control handle,
install the pivot bolt and pivot adjusting knob into
tower.
RCPH10TLB338ABL 1
5. Install the control mounting screws in the tower.

6. Stand cover up beside control tower, connect electri-
cal connector to chassis harness.
7. Start the machine and operate the hydraulics.
8. Make sure that the remote control valve operates the
backhoe correctly.
9. Check for leaks at the remote control valve.
10. Turn the machine off.
11. Install the heat shield in the tower.
RCPH10TLB339ABL 2
12. Install cover on tower, connect electrical connector.
RCPH10TLB337ABL 3
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13. On the right tower (facing rear of machine) install the

tilt levers.
RCPH10TLB335ABL 4
14. Install the retaining plate, two mounting screws and

washers. Pull the rubber boot down and secure it to
the retaining plate.
15. Install the wrist rest.
16. Install floor boards and floor mat (if equipped).
17. Start the machine and place the pilot control switch
in the on position.
18. Operate the remote control valves for ten minutes to
remove any air from the system.
19. Check the level of hydraulic oil in the reservoir and
add as required. RCPH10TLB334ABL 5
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Remote control valve - Remove - Loader control valve

and wires. Seal disconnected hoses and fittings with caps
and plugs.
parking brake.
engine.
3. Move the loader control lever in all directions to re-
lease the pressure from the loader hydraulic circuits.
4. Remove the two screws from the right hand side of
the floor mat.
RCPH10TLB318ABL 1
5. Pull the floor mat away from the loader control cover.
RCPH10TLB076AAM 2
6. Remove the boot retaining screw.
RCPH10TLB447ABL 3
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7. Pull the cover off of the louver assembly.
RCPH10TLB314ABL 4
8. Push the four tabs inward while pulling the louver

assembly out.
RCPH10TLB312ABL 5
9. Pull the louver assembly (1) off of the hose (2) and
push the hose back into the cover.
RCPH10TLB313ABL 6
10. Pull the rubber boot upward turning it inside out. This
will allow the boot to slide through the hole in the
cover.
11. Remove the three bolts which fasten the loader con-
trol cover to the cab frame. Remove the cover.
RCPH10TLB075AAM 7
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12. Remove the bolts (1) from the loader control plate.
Remove the front plate (2) first then back plate (3).
NOTE: The back plate is sealed with silicone sealant.
RCPH10TLB309ABL 8
RCPH10TLB308ABL 9
13. Remove front cab floor plate (2).
RCPH10TLB001BAN 10
1. Cab floormat 3. Loader control lever split floor plate

2. Front cab floor plate
14. Disconnect the lever linkage rods from the valve.
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15. Remove the cap (1) from the hydraulic reservoir.

This will reduce the hydraulic oil loss as the hoses
and tubes are removed from the loader control valve.
RCPH10TLB428AAF 11
16. If machine is equipped with a pilot controlled clam

bucket, tag and disconnect hoses to clam controls
(1).
RCPH10TLB004GAN 12
17. Remove skid plate from machine.
RCPH10TLB077AAM 13
18. Disconnect the wiring for the magnetic detent located

on the bucket section of the loader control valve.
RCPH10TLB327ABL 14
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19. Disconnect and remove tubes (1), disconnect hoses

(2), and disconnect tubes (3) from the fittings on the
loader control valve. Install caps on the fittings and
plugs in the tubes and hoses.
580SN, 580SN-WT and 590SN will have steering
and coupler (if equipped) hoses connected to the
loader valve.
NOTE: Cab is removed for clarity only.
RCPH10TLB328ABL 15
20. Connect acceptable lifting equipment to the loader

control valve.
21. Loosen and remove the three bolts (1), washers (2)
and spacers (3) that fasten the loader control valve
to the chassis.
NOTE: Do not loose spacers that are behind loader valve.
580N 2 spool, does not have spacers.
22. Remove the loader control valve from the machine.
RCPH10TLB045GAM 16
Next operation:
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Remote control valve - Install - Loader control valve

Prior operation:
Remote control valve - Remove - Loader control valve (35.204)
1. Use acceptable lifting equipment to put the loader

control valve into position in the machine.
2. Install the three bolts (1), washers (2), and spacers
(3) to fasten the loader control valve to the chassis.
RCPH10TLB045GAM 1
NOTE: Do not loose spacers that are behind loader valve.

NOTE: 580N 2 spool, does not have spacers.
3. Remove the lifting equipment from the loader control
valve.
4. Remove caps from the fittings and plugs from the
tubes and hoses. Connect tubes (3), connect hoses
(2), install and connect tubes (1) to the fittings on the
loader control valve.
NOTE: Cab is removed for clarity only.
RCPH10TLB328ABL 2
5. Connect the wiring for the magnetic detent.
RCPH10TLB075AAM 3
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6. Install skid plate on machine.
RCPH10TLB326ABL 4
If machine is equipped with a pilot controlled clam bucket,

connect hoses to clam controls, remove tags install during
disassembly.
RCPH10TLB445ABL 5
7. Install the hydraulic reservoir cap.
RCPH10TLB428AAF 6
8. Connect the lever linkage rods to the valves.
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9. Install front cab floor plate (1).
RCPH10TLB001BAN 7
1. Front cab floor plate

2. Loader control lever split floor plate
3. Floor mat
10. Put a bead of RTV silicone sealant on the mating

surface of the back plate (3) and install. Install the
front plate (2) and tighten the bolts (1).
RCPH10TLB309ABL 8
RCPH10TLB308ABL 9
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11. Put the louver assembly (1) on the hose (2) and push
into the cover.
RCPH10TLB313ABL 10
12. Push the cover on the louver assembly.
RCPH10TLB314ABL 11
13. Install the boot and retaining screw.
RCPH10TLB447ABL 12
14. Put the floor mat back into place and install the two
screws.
NOTE: See Throttle control - Adjust - Throttle linkage
adjustment (55.525). Adjust the loader control linkage as
required.
15. Start the engine and let it run at low idle. Activate the
loader control lever for both the bucket and lift func-
tion. If equipped, activate the clam function. Hold in
each position for 15 - 20 s.
engine.
RCPH10TLB318ABL 13
17. Check for oil leakage at the loader control valve.
as required. See Capacities () for specifications.
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Remote control valve - Remove - Clam control pilot valve

and wires. Close disconnected hoses and fittings with caps
and plugs.
parking brake.
engine.
3. Move the loader control lever in all directions to re-
lease the pressure from the loader hydraulic circuits.
4. Turn the ignition switch to the ON position and ac-
tivate the clam control several time to release any
pressure in the accumulator, turn the ignition switch
OFF.
5. Tag and disconnect hoses from the clam control
block.
RCPH10TLB004GAN 1
6. Tag and disconnect the electrical connectors from

the solenoids.
7. Remove the mounting bolts, remove the clam control
block from the loader valve guard.
Next operation:
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Remote control valve - Install - Clam control pilot valve

Prior operation:
1. Install the control block on the loader valve guard.

2. Connect hoses and solenoid wires, remove tags in-
stalled during removal.
3. Start and operate clam control, open and close the
clam three times.
4. Stop the machine, check the valve for leaks.
5. Check oil level in the reservoir, add oil as required.
RCPH10TLB040GAM 1
(1) Pump pressure hose (5) Clam control block

(2) Pressure hose to spool (6) Pressure hose to spool
(3) Pressure to clam manifold (7) Loader valve
(4) Accumulator (8) Return to reservoir
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Remote control valve - Remove - Pilot controls backhoe valve

WARNING
Pressurized system!
Before attempting any service procedure, it is your responsibility to know the number of accumulators
on the machine, and the correct procedure for releasing the pressure of each accumulator.
W0136A
1. Park the machine on a level surface, lower stabilizers

and loader bucket to the floor.
2. Turn off the engine, turn the ignition switch to the on
position and the pilot control switch to the on position.
3. Move the pilot controls in all directions several times
to release the accumulator pressure, move the
loader controls in all directions to release pressure
on the loader.
4. Turn pilot control switch and ignition switch off.
5. Remove the ROPS Cab/Canopy from the machine,
see Roll Over Protective Structure (ROPS) frame
- Remove (90.114).
6. Disconnect the hydraulic hoses at the swing cylin-
ders that come from the swing cushioning valve, cap
the fittings and plug the hoses.
7. Tag and disconnect all hydraulic hoses from the con-
trol valve, cap and plug all hoses and fittings.
8. Disconnect the electrical connectors for the pilot unit.
RCPH10TLB331ABL 1
9. Disconnect the backup alarm.
RCPH10TLB329ABL 2
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RCPH10TLB330ABL 3
10. Attach suitable lifting equipment to the pilot control,

remove the mounting bolts from the pilot control.
NOTICE: Do not attach lifting equipment to any hydraulic
tubes.
11. Loosen and remove the mounting bolts from the pilot
control mounting bracket.
12. Slowly raise the control unit from the machine, make
sure control unit does not become entangled on the
frame.
13. Place the control unit on a bench, block unit to ensure
that no tubing is bent.
Next operation:
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Remote control valve - Install - Pilot controls backhoe valve

Prior operation:
1. Attach suitable lifting equipment to the pilot control.

NOTICE: Do not attach lifting equipment to any hydraulic
tubes.
2. Slowly lower the control unit into the machine, make
sure control unit does not become entangled on the
frame.
3. Install and tighten the mounting bolts for the pilot con-
trol bracket.
4. Connect the backup alarm.
RCPH10TLB330ABL 1
RCPH10TLB329ABL 2
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5. Connect the electrical connectors for the pilot unit.

6. Remove caps and plugs, connect all hydraulic hoses
to the control valve.
7. Connect the hydraulic hoses to the swing cylinders.
8. Install the ROPS Cab/Canopy on the machine, refer
to section Roll Over Protective Structure (ROPS)
frame - Install (90.114).
9. Start the machine and place the pilot control switch
in the on position.
10. Operate the pilot control valves for ten minutes to
remove any air from the system. RCPH10TLB331ABL 3
NOTE: It may take several temperature cycles of the ma-

chine and several hours of operation to fully remove all of
the air.
11. Check the level of hydraulic oil in the reservoir and
add oil as required.
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Remote control valve - Remove - Mechanical controls backhoe

valve

and tubes. Close disconnected hoses, tubes and fittings
with caps and plugs.
1. Park the machine on a level surface and lower the
loader bucket to the floor.
2. If the backhoe is equipped with an Extendahoe, in-
stall the Extendahoe lock pin.
3. Lower the stabilizers until the stabilizer pads just
touch the floor.
4. Extend the backhoe straight behind the machine with
the backhoe bucket resting on the ground.
5. Stop the engine and apply the parking brake.
6. Move the backhoe control levers in all directions until
all hydraulic pressure has been removed from the
backhoe hydraulic circuits.
7. Remove the four retaining screws.
RCPH10TLB316ABL 1
8. Remove the bolts (1) which fasten the backhoe con-

trol tower covers.
RCPH10TLB317ABL 2
1. Bolt 2. Front cover 3. Rear cover
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9. Pull the rubber boot (1) up and remove the rear cover
(3) and front cover (2).
RCPH10TLB315ABL 3
10. Remove the backhoe control tower covers (2) and

(3).
11. If equipped, remove the cab floor mat (1). Remove
the rear cab floor plate (2).
12. Attach identification tags to the linkage for the back-
hoe control valve.
13. Disconnect the linkage rods from the spools on the
backhoe control valve.
14. Remove the bolts which fasten the backhoe control
tower assembly to the valve mounting brackets.
15. Remove the backhoe control tower assembly from
the machine.
RCPH10TLB078GAL 4

tubes are removed from the valve.
17. Disconnect the hoses and tubes from the backhoe
control valve. Install caps on the fittings and plugs in
the hoses and tubes.
18. Connect acceptable lifting equipment to the backhoe
control valve.
19. Remove the bolts that fasten the backhoe control
valve right and left mounting brackets to the chas-
sis.
RCPH10TLB428AAF 5
20. Remove the backhoe control valve from the ma-
chine.
Next operation:
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Remote control valve - Install - Mechanical controls backhoe valve
Prior operation:
1. Using acceptable lifting equipment, place the back-

hoe control valve in the machine.
2. Align the left and right valve mounting brackets with
the chassis mounting holes. Install the bolts.
3. Remove the lifting equipment.
4. Connect all hoses and tubes.
5. Install the hydraulic reservoir cap.
6. Install the backhoe control tower assembly. Use the
bolts to fasten the backhoe control tower to the valve
mounting brackets.
7. Connect the linkage rods to the spools on the back-
hoe control valve.
8. Install the rear cab floor plate (1). If equipped, install
the cab floor mat (2).
RCPH10TLB078GAL 1
9. If the machine is equipped with auxiliary hydraulics,

connect the control cables to the backhoe control
tower.
10. Install the backhoe control tower assembly covers (2)
and (3).
RCPH10TLB317ABL 2
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11. Install the four retaining screws.
RCPH10TLB316ABL 3
12. Start the engine and activate each of the backhoe

control levers. Hold each lever over relief in each
direction for 15 - 20 s.
13. Stop the engine. Check for oil leaks at the backhoe
control valve.
as required.
RCPH10TLB453ABL 4
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Remote control valve - Check - Pilot control unit

NOTE: Remove control unit from machine, see Remote control valve - Remove (35.204).
1. Loosen the handle jam nut, unscrew handle from
control unit.
NOTE: During assembly torque jam nut to 40 N·m +/- 4
(29.5 lb ft +/- 3).
RCPH10TLB452ABL 1
2. Place the control handle in a soft jawed vise.
RCPH10TLB428ABL 2
3. Loosen the cardan.
RCPH10TLB429ABL 3
4. Remove the cardan from the control unit.
RCPH10TLB430ABL 4
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5. Keep all shims for the cardan together for use during
assembly.
NOTE: During assembly use LOCTITE® 262 on threads and
torque cardan bolt to 40 N·m +/- 4 (29.5 lb ft +/- 3).
RCPH10TLB431ABL 5
6. Remove the retaining plate from the control unit.
RCPH10TLB432ABL 6
7. Mark the guides and the body so components will be

placed into the same position.
RCPH10TLB433ABL 7
8. Insert the end of a thin screwdriver between the guide

and the body, carefully lift the guide to remove it from
the body.
RCPH10TLB434ABL 8
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9. Mark the retainer cups.
RCPH10TLB435ABL 9
10. Remove the regulation units.
RCPH10TLB436ABL 10
11. Push down on the retainer cup and twist the plunger
out of the cup.
RCPH10TLB440ABL 11
12. Remove the spring and shims from the plunger.
RCPH10TLB441ABL 12
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13. Inspect the regulation units, repair or replace as nec-

essary.
RCPH10TLB442ABL 13
1. Dust boot 5. Retainer cup

2. Plunger 6. Spring
3. Spring 7. Plunger
4. Plunger 8. Spring
14. Turn control unit over in the vise and remove the
lower body.
RCPH10TLB437ABL 14
15. Remove and replace the “O” rings.
RCPH10TLB439ABL 15
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16. Install bolt and torque to 50 N·m +/- 5 (37 lb ft +/-

3.5).
NOTICE: Make sure notches are aligned during assembly.
RCPH10TLB438ABL 16
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Index

Remote control valve - Check - Pilot control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Remote control valve - Component diagram - Pilot control color codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Remote control valve - Drawing 580N Mechanically Controlled Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remote control valve - Drawing 580SN, 580SN WT and 590SN Mechanically Controlled Machines . . . . . . . . . . . 5
Remote control valve - Drawing Remote Clam Valve for 580SN, 580SN WT and 590SN with Pilot Controlled Back-
hoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remote control valve - Install - Clam control pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Remote control valve - Install - Loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Remote control valve - Install - Mechanical controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Remote control valve - Install - Pilot controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Remote control valve - Install - Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remote control valve - Remove - Clam control pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Remote control valve - Remove - Loader control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remote control valve - Remove - Mechanical controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Remote control valve - Remove - Pilot controls backhoe valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Remote control valve - Remove - Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Reservoir, cooler, and filters - 300
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
Accumulator
General specification - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Oil filters
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Accumulator
Exploded view - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Detailed view - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Accumulator
Check - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Discharging - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Disassemble - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspect - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure test Right Solenoid Valve for Ride Control (Accumulator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure test Checking the Nitrogen Charge in the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Charging - Charging the Accumulator With Dry Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSTIC
Oil reservoir
Testing - Hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Hydraulic systems - Reservoir, cooler, and filters
Accumulator - General specification - Ride control

Torque, accumulator charging valve cap 1.1 N·m (10 lb in)
Weight (approximate) 4.9 kg (10.8 lb)
Accumulator - Special tools - Ride control

Nitrogen charging kit with regulator 380001737
RCIL10TLB016BAF 1
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Oil filters - Sectional view
RCPH10TLB004GAM 1
(1) Inlet (5) Filter

(2) To Reservoir (6) Filter Bypass Valve
(3) To Oil Cooler (7) Restriction Indicator
(4) From Ride Control Valve (8) Cooler Bypass Valve
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Accumulator - Exploded view - Ride control
RCPH10TLB015FAL 1
1. Tube 5. Quad ring 9. Guard

2. Gland with gas valve 6. O-ring 10. Gas valve assembly
3. Piston 7. Backup ring, if used 11. Gland without gas valve
4. Seal 8. Cap screw
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Accumulator - Detailed view - Ride control
RCIL10TLB005GAF 1
1. Tube 5. Quad ring 9. Guard

2. Gland with gas valve 6. O-ring 10. Gas valve assembly
3. Piston 7. Backup ring, if used 11. O-ring
4. Seal 8. Cap screw 12. Gland without gas valve
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Accumulator - Check - Ride control

1. Ensure that the oil side of the accumulator is com-
pletely discharged.
1. Put the ride control switch in the ON position.
2. Lower the loader to the floor.
3. Put the loader control lever in the FLOAT posi-
tion.
5. Put the key switch in the ON position.
6. Move the loader control lever in all directions to
release any pressure in the hydraulic circuits.
7. Put the loader control lever in the FLOAT posi-
tion.
NOTICE: Ensure you leave the ride control switch and the
key switch in the ON position and the loader control lever
in the FLOAT position.
2. Close valve (B) and valve (C) on the nitrogen charge
with regulator kit 380001737.
RCIL10TLB016BAF 1
3. Turn the stem out of valve (F) until the stem stops.
4. If you have not already done so, remove the cap
screws and guard from the accumulator.
5. Connect valve (F) to the valve stem.
6. Make sure that valve (D) is open.
7. Turn the stem into valve (F) and read the pressure on
gauge (E). The pressure must be 24 - 26 bar (350 -
375 psi).
8. If the pressure is too low, charge the accumulator
with dry nitrogen. Refer to Accumulator - Charging
- Ride control (35.300).
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Accumulator - Charging - Ride control

Prior operation:
Accumulator - Check - Ride control (35.300)
Prior operation:
Keep the nitrogen charge with regulator kit 380001737 attached to the machine.
1. Slowly turn valve (A) counter-clockwise to lower the

pressure.
2. Open valve (B).
3. Close valve (C) and valve (D).
4. Turn the stem out of valve (F) until the stem stops
moving.
RCIL10TLB016BAF 1
5. Disconnect valve (F) from the valve stem on the ac-

cumulator.
6. Connect the nitrogen charge with regulator kit to a
dry nitrogen tank.
7. Slowly turn valve (A) clockwise and read gauge (E).
8. When the pressure is 24 - 26 bar (350 - 375 psi),
stop turning valve (A).
9. If the pressure increases above 26 bar (375 psi),
quickly open and close valve (D) and read gauge
(E). The pressure shown on gauge (E) is the charge
pressure.
10. Check gauge (E) again.
11. If the pressure is still too high, turn valve (A) coun-
terclockwise a small amount and quickly open and
close valve (D).
12. Repeat steps 10 and 11 until the pressure is within
specification.
13. Connect valve (F) to the valve stem on the accumu-
lator.
14. Turn the stem into valve (F) until the stem stops mov-
ing.
15. Open valve (D) to charge the accumulator.
16. After the accumulator stops charging, turn the stem
out of valve (F) until the stem stops moving.
17. Close valve (B).
18. Disconnect the nitrogen charge with regulator kit
from the valve stem in the accumulator
19. Install the cap on the valve stem.
20. Install the guard and cap screws.
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Accumulator - Discharging - Ride control

NOTICE: Always discharge the nitrogen in the accumulator before disassembling the accumulator.
1. Use the nitrogen charging with regulator kit
380001737 to discharge the accumulator. The tool
must be disconnected from the nitrogen tank (7).
2. Close valve (B), valve (C) and valve (D).
NOTICE: To help prevent equipment damage, the low
pressure gauge (valve (C)) must be shut off during high
pressure applications of 10 bar (150 psi) and above.
3. Turn the knob counter-clockwise on valve (A) to ad-
just the regulator to the minimum pressure setting.
4. Turn the T-handle on valve (F) until it is fully out.
5. Remove the guard and cap from the accumulator
charging stem (8). RCIL10TLB016BAF 1
6. Connect valve (F) to the stem on the accumulator.

7. Turn the T-handle inward on valve (F) to engage the
pin in the valve stem.
8. Open valve (D) and check the charge pressure on
gauge (E).
9. Partially open valve (B) to discharge the accumula-
tor. The accumulator charge will bleed down through
the regulator.
10. Once the accumulator is fully discharged, disconnect
valve (F) from the accumulator stem.
Next operation:
Accumulator - Disassemble - Ride control (35.300)
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Accumulator - Disassemble - Ride control

1. Fasten the accumulator tube (1) in a vise with soft
jaws. Be careful not to damage the tube.
2. Loosen and remove the gland with the gas valve (2)
from the tube end.
NOTICE: The gland with the gas valve must be removed
first.
3. Loose and remove the glad without the gas valve (12)
from the other end of the tube.
4. Use a rod and push out the piston (3).
NOTE: This piston is at the same end of the tube that you
removed the gland with the gas valve.
5. Remove and discard the seals (4) and the quad ring
(5) from the piston.
6. Remove and discard the O-rings (6) and the backup
rings (7), if used, from the glands.
7. Loosen and remove the cap screws (8) and the guard
RCIL10TLB018BAF 1
(9).
8. Loosen and remove the gas valve assembly (10)
from the gland.
9. Remove and discard the O-ring (11) from the gas
valve assembly.
10. Remove the cap, the body, and the valve core from
the gas valve assembly.
Next operation:
Accumulator - Inspect (35.300)
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Accumulator - Inspect - Ride control

Prior operation:
Accumulator - Disassemble (35.300)
1. Discard parts removed from the gland (2) and (4) and
piston (3).
2. Clean all parts in cleaning solvent free of dirt and
contaminates.
3. Inspect the inside of the tube (1) for deep grooves
and other damage. If there is any damage, a new
accumulator must be used.
4. Remove small scratches on the piston (3), gland (2)
and (14) or tube (1) with an emery cloth of 400 or finer
grit. Rotate the emery cloth with a circular motion
when trying to removing the scratches. Inspect the
gland ends of the tube for sharp edges that will cause
damage to the seals, quad ring, or O-rings. Remove
any sharp edges as needed.
5. Inspect the gland (9) for rust. Clean and remove the
rust as required.
6. Inspect the piston (3) for damage or wear. If the
piston (3) is damaged or worn, a new accumulator
must be used.
7. Inspect the gland ends of the tube (1) for sharp
edges that will damage the seals (4), quad ring (5) or
O-rings (6). Remove any sharp edges as required.
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RCPH11TLB007GAM 1
(1) Tube (8) Cap Screw

(2) Gland with Gas Valve (9) Guard
(3) Piston (10) Gas Valve Assembly
(4) Seal (11) Cap
(5) Quad Ring (12) Valve Core
(6) O-ring (13) Body
(7) Backup Ring, if used (14) Gland without Gas Valve
Next operation:
Accumulator - Assemble (35.300)
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Accumulator - Assemble
Prior operation:
Accumulator - Inspect (35.300)
1. Install a new quad ring (6) on the piston (3).
RCIL10TLB018BAF 1
(1) Tube (8) Cap Screw

(2) Gland with Gas Valve (9) Guard
(3) Piston (10) Gas Valve Assembly
(4) Seal (11) Cap
(5) Quad Ring (12) Valve Core
(6) O-ring (13) Body
(7) Backup Ring, if used (14) Gland without Gas Valve
2. Install a new seals (4) on each end of the piston (3).

3. Lubricate the bore of the tube (1) and the piston (3)
with clean oil.
NOTE: The piston must be installed slowly to prevent dam-
age to the quad ring on the threads in the tube.
4. Start the piston (3) into the gas valve end of the tube
(1). A soft hammer and wood block may be used to
drive the piston (3) into the tube (1). See the illustra-
tion below of the correct piston installation. Carefully
drive the piston (3) at least 51 mm (2 in) into the
tube (1). Keep pressure against the piston (3) when
driving the piston (3) into the tube (1). This will help
prevent damage to the quad ring (5).
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5. If used, install a new backup ring (6) on the gland (2).

Make sure the backup ring (6) is installed as shown
in the illustration below.
RCPH11TLB001BAM 2
(6) O-ring (7) Backup ring

(A) To thread end of gland
6. Install the O-ring (6) next to the backup ring (7) as

shown in the illustration above. If a backup ring (7) is
not used, install an O-ring in the grove on the piston.
7. Lubricate the o-ring (6) and backup ring (7) with clean
oil and start the gland (2) into the tube (1).
RCIL10TLB018BAF 3
8. Fasten the tube (1) in the vise and tighten the gland.
9. repeat steps 5 through 8 for the other end of the tube
(1).
10. Install a new o-ring (6) on the body (13) of the gas
valve assembly (10).
11. Install the valve core (12) in the body (13).
12. Lubricate the O-ring (6) with clean oil and install and
tighten the gas valve assembly (10) in the gland.
13. Install the cap (11).
14. Charge the accumulator with dry nitrogen. Refer to
Accumulator - Charging - Ride control (35.300).
15. Install the guard (9) and cap screws (8).
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RCPH11TLB007GAM 4
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Accumulator - Pressure test Right Solenoid Valve for Ride Control

(Accumulator)
RCPH10TLB008GAM 1
(1) Ride Control Valve (4) Tube, Ride Control to P2 Port

(2) Accumulator (5) Tube, Ride Control to P1 Port
(3) Tube, Ride Control to Accumulator (6) Tube, Ride Control T Port
1. Verify that the oil side of the accumulator is com-

pletely discharged by doing the following:
A. Put the ride control switch in the ON position.
B. Lower the loader to the floor. Put the loader
control lever in the float position.
C. Stop the engine. Put the key switch in the ON
position.
D. Move the loader control lever in all directions to
release any pressure in the hydraulic circuits.
Put the loader control lever in the float position.
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2. Put the ride control switch and key switch in the OFF
position.
3. Put the loader control lever in the NEUTRAL position.
4. Disconnect the tube (3) between the right solenoid
valve (1) and the accumulator (2) at the right solenoid
valve.
5. Remove the adjustable elbow fitting in the right sole-
noid valve. Install an adjustable tee in that location.
6. Connect the tube from the accumulator to the ad-
justable tee fitting in the right solenoid valve.
7. Connect DATAR to the fitting on the right solenoid
valve. Connect TA092 pressure transducer to the
fitting. Set the transducer to 60 Bar.
NOTE: If DATAR is not available, a pressure gauge of 27580 kPa (4000 psi) or greater can be used.
8. Put the ride control switch in the OFF position. Start
and Run the engine at low idle.
9. Move the loader control lever to the RAISE position
while monitoring the pressure value. The pressure
should be approximately 0 kPa (0 psi). If the pres-
sure reading indicates more than 172 kPa (25 psi)
repair or replace the right solenoid valve for ride con-
trol.
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Accumulator - Pressure test Checking the Nitrogen Charge in the

Accumulator
1. Make sure that the oil side of the accumulator is com-

pletely discharged by doing the following.
A. Put the ride control switch in the ON position.
B. Lower the loader to the floor. Put the loader
control lever in the float position.
C. Stop the engine. Put the key switch in the ON
position.
D. Move the loader control lever in all directions to
release and pressure in the hydraulic circuits.
Put the loader control lever in the FLOAT posi-
tion.
E. Leave the ride control switch and key switch in
the ON position.
F. Leave the loader control lever in the FLOAT
position.
2. Close valves (B) and (C) on the nitrogen charging kit.
3. Turn the stem out of valve (F) until the stem stops.
4. Remove the cap screws and guard from the accumu-
lator.
5. Remove the cap from the valve stem on the accumu-
lator.
6. Connect valve (F) to the valve stem.
7. Verify that valve (D) is open.
8. Turn the stem into valve (F) and read the pressure
on gauge (E). The pressure must be between 2413 -
2585 kPa (350 - 375 psi). If the pressure is too low,
charge the accumulator with dry nitrogen.
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Accumulator - Charging - Charging the Accumulator With Dry

Nitrogen
NOTE: Verify the pressure in the accumulator according to the instructions in Accumulator - Pressure test (35.300).
1. Slowly turn the valve (A) counterclockwise to lower

the pressure.
2. Open valve (B). Close valves (C) and (D).
3. Turn the stem out of valve (F) until the stem stops
moving. Disconnect valve (F) from the valve stem
on the accumulator.
4. Connect the nitrogen charging kit to a dry nitrogen
tank.
5. Slowly turn valve (A) clockwise and read gauge (E)
until the pressure is 2413 - 2585 kPa (350 - 375 psi).
6. If the pressure increases above 2585 kPa (375 psi),
quickly open and close valve (D) and read gauge
(E). If the pressure is still too high, turn valve (A)
counterclockwise a small amount and quickly open
and close valve (D). The pressure shown on gauge
(E) is the charging pressure.
7. Connect valve (F) to the stem on the accumulator.
Turn the stem into valve (F) until the stem stops mov-
ing and open valve (D) to charge the accumulator.
8. After the accumulator stops charging, turn the stem
out of valve (F) until the stem stops moving.
9. Close valve (B) and disconnect the nitrogen charging
kit from the valve stem on the accumulator.
10. Install the cap on the valve stem. Install the guard
and cap screws.
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Oil reservoir - Testing - Hydraulic oil reservoir

Visually check the machine for oil Yes, verify correct movement of the Fill the hydraulic reservoir with the oil
leakage and damaged or missing pilot controls. Check the operation specified in Capacities ()
parts. Repair or replace any dam- of the machine, does the machine
aged or missing parts. operate correctly.
Check
Check the oil level in the hydraulic
reservoir. Is the oil level correct?
Does the machine operate correctly? Yes, troubleshooting complete. Heat the oil in the hydraulic system to
operating temperature. Operate the
machine to find which circuits have
problems.
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Index

Accumulator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Accumulator - Charging - Charging the Accumulator With Dry Nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Accumulator - Charging - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Accumulator - Check - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Accumulator - Detailed view - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accumulator - Disassemble - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Accumulator - Discharging - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Accumulator - Exploded view - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Accumulator - General specification - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Accumulator - Inspect - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Accumulator - Pressure test Checking the Nitrogen Charge in the Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Accumulator - Pressure test Right Solenoid Valve for Ride Control (Accumulator) . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Accumulator - Special tools - Ride control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Oil filters - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Oil reservoir - Testing - Hydraulic oil reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Safety and main relief valves - 350
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Main relief valve

Drawing Swing and Bi-Dir Aux section, Backhoe Control Valves for 580N, 580SN, 580SN WT and 590SN
Pilot Controlled Machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drawing Relief Valve, Loader Dump, Backhoe Swing on mechanically controlled Backhoes . . . . . . . . . . 4
Drawing Relief Valve, 4000 psi Spike Clipper for Loader Valve on 580SN, 580SN WT and 590SN machines
with mechanical backhoe controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Drawing Single Stage Relief Valve, 580 Main Relief with mechanical backhoe controls . . . . . . . . . . . . . . 6
Drawing Relief Valve, Main System Dual Stage for 580N with Pilot Controlled Backhoe . . . . . . . . . . . . . . 7
Drawing Load Sense Relief Valve, 580N with Pilot Controlled Backhoe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
Main relief valve

Adjust Main Relief Valve, 580N with mechanical controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove - Circuit relief valve, 580N, 580SN, 580SN WT and 590SN machines with Pilot Controls (Swing
and Bi-Directional relief valves only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cleaning Relief Valve, Backhoe Main Relief Valve, 580N with Pilot Backhoe Controls . . . . . . . . . . . . . . 12
Pressure test Loader and Backhoe Main Relief Valve for 580N mechanical machines only. Loader Main
Relief Valve for 580N machine with Pilot Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Pressure test - Load Sense Relief Valve for 580N Backhoe relief Pilot Controls only . . . . . . . . . . . . . . . . 14
Adjust - 580N Backhoe relief Pilot Controls only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Adjust Dual Stage Relief Valve, 580N Pilot Controlled Backhoe Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replace - Load Sense Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Hydraulic systems - Safety and main relief valves
Main relief valve - Drawing Swing and Bi-Dir Aux section, Backhoe
Control Valves for 580N, 580SN, 580SN WT and 590SN Pilot
Controlled Machines.
RCPH10TLB042GAM 1
1. Circuit relief valve 4. Spool

2. Dampened compensator (Bi-Aux) 5. Centering spring
3. Solid compensator (Swing) 6. Check valve
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Main relief valve - Drawing Relief Valve, Loader Dump, Backhoe

Swing on mechanically controlled Backhoes
RCPH10TLB006FAM 1
1. O-ring 4. Plunger 7. Cap

2. Poppet - Relief Valve 5. Back up Ring 8. Nut
3. Spring 6. Sleeve, Poppet
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Main relief valve - Drawing Relief Valve, 4000 psi Spike Clipper
for Loader Valve on 580SN, 580SN WT and 590SN machines with
mechanical backhoe controls.
RCPH10TLB007FAM 1
1. O-ring 4. Back up Ring 7. Screw, Adjust

2. Poppet 5. Washer, Flat 8. Plug
3. Spring 6. Nut 9. Seal, Special
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Main relief valve - Drawing Single Stage Relief Valve, 580 Main
Relief with mechanical backhoe controls
RCPH10TLB008FAM 1
1. O-ring 4. Piston 7. Screw, Adjust

2. Poppet 5. Back up Ring 8. Nut, Special
3. Spring 6. Plug
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Main relief valve - Drawing Relief Valve, Main System Dual Stage for
580N with Pilot Controlled Backhoe
RCPH10TLB009FAM 1
1. O-ring 4. Piston 7. Screw, Adjust

2. Poppet 5. Back up Ring 8. Nut, Special
3. Spring 6. Plug 9. Special Fitting, ORFS
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Main relief valve - Drawing Load Sense Relief Valve, 580N with Pilot
Controlled Backhoe
RCPH10TLB057FAM 1
1. O-ring 3. Spring 5. Adjustment screw

2. Poppet 4. Back up Ring 6. Jam Nut
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Main relief valve - Adjust Main Relief Valve, 580N with mechanical
controls
1. The main relief valve is in the inlet section of the
loader control valve. Loosen the locknut (1) on the
main relief valve. Turn the adjusting screw (2) clock-
wise to increase the pressure and counterclockwise
to decrease the pressure.
2. Check the pressure again.
3. If the main relief valve pressure is very low and the
steering relief pressure is normal, repeat test, Main
relief valve - Pressure test (35.350) with the bucket
bottomed out.
4. When the pressure is correct, tighten the lock nut (1).
RCPH10TLB001CAM 1
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Main relief valve - Remove - Circuit relief valve, 580N, 580SN,

580SN WT and 590SN machines with Pilot Controls (Swing and
Bi-Directional relief valves only)
Prior operation:
Pump control valves - Cleaning (35.102)
NOTE: This procedure is for the Swing and Bi-Dir relief valves only. The Boom, Dipper, Bucket and Loader bucket
use a different design that cannot be disassembled.
NOTE: The following procedures are for reference only, the relief valves are replaced as an assembly and are not
repairable.
1. Loosen the jam nut on relief valve.
RCPH10TLB418ABL 1
2. Remove the adjusting screw and jam nut.
RCPH10TLB419ABL 2
3. Remove the spring and poppet.
RCPH10TLB420ABL 3
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4. Loosen the plug.
RCPH10TLB421ABL 4
5. Remove the plug from the body.
RCPH10TLB422ABL 5
6. Remove the spring and poppet from the body.
RCPH10TLB423ABL 6
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Main relief valve - Cleaning Relief Valve, Backhoe Main Relief Valve,
580N with Pilot Backhoe Controls
1. Loosen the locking nut for the adjusting screw. See
Main relief valve - Drawing (35.350) for details.
RCPH10TLB424ABL 1
2. Loosen the adjusting screw.

NOTE: The adjusting screw will not come out completely.
RCPH10TLB425ABL 2
3. Loosen the adjusting screw retaining nut.
RCPH10TLB426ABL 3
4. Remove the locking nut from the adjusting screw,

remove the retaining nut from the adjusting screw,
remove the spring and poppet from the body.
RCPH10TLB427ABL 4
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Main relief valve - Pressure test Loader and Backhoe Main Relief
Valve for 580N mechanical machines only. Loader Main Relief Valve
for 580N machine with Pilot Controls.
2. The hydraulic oil temperature must be 51 °C (124 °F).
To heat the hydraulic oil, do the following steps:
3. A. With the engine running at full throttle, hold the
loader control lever in the ROLLBACK position
for 15 seconds.
B. Put the loader control lever in the NEUTRAL
C. Repeat steps A and B until the temperature
4. Connect DATAR. Connect TA092 pressure trans-
ducer to the quick disconnect fitting at the EF port
on the pump. Set the transducer to 600 Bar.
NOTE: If DATAR is not available, use a pressure gauge of
27580 kPa (4000 psi) or greater. Connect the pressure
gauge to the quick disconnect fitting.
5. Run the engine at full throttle. Hold the loader con-
trol lever in the RAISE position until the loader stops
moving.
6. Hold the loader control lever in the RAISE position
and read the pressure. Then release the loader con-
trol lever and decrease the engine speed to low idle.
Stop the engine.
7. Compare the reading with specifications, Hydraulic
systems - General specification (35.000). If the
readings are not correct, adjust the main relief valve.
For 580N with mechanical controls see Main relief
valve - Adjust Main Relief Valve, 580N with me-
chanical controls (35.350).
For 580N with pilot backhoe controls see Main relief
valve - Adjust Dual Stage Relief Valve, 580N Pilot
Controlled Backhoe Valves (35.350).
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Main relief valve - Pressure test - Load Sense Relief Valve for 580N
Backhoe relief Pilot Controls only
Prior operation:
Main relief valve - Pressure test Loader and Backhoe Main Relief Valve for 580N mechanical machines only.
Loader Main Relief Valve for 580N machine with Pilot Controls. (35.350)
1. Park machine on level and firm surface.

2. Put backhoe in transport position. Lower loader
bucket to ground.
3. Stop engine. Turn ignition and pilot switch to ON
position. Operate pilot and loader controls to relieve
pressure in system.
4. Ensure oil temperature is at operating temperature.
Do the following:
1. Start engine. Run engine at full throttle and po-
sition boom in travel lock position. Hold boom
control lever in the lower position for 15 sec-
onds.
2. Put boom control lever in NEUTRAL position
for 15 seconds.
3. Repeat steps A and B until oil temperature
reaches minimum of 51 °C (123.8 °F).
5. Use adapter 190119A1 to connect DATAR. Connect
TA092 pressure transducer to "M" port. Set trans-
ducer to 600 bar on backhoe valve.
NOTE: If DATAR is not available, use pressure gauge capable of minimum 344.8 bar (5000 psi) Connect to "M" port.
Use adapter 190119A1 on backhoe valve.
6. Run engine at high idle. Hold a stabilizer over relief.
Record pressure result.
7. Compare to specification. See Hydraulic systems -
General specification (35.000).
8. If pressure setting is not in specification, adjust load
sense relief valve. See Main relief valve - Adjust -
580N Backhoe relief Pilot Controls only (35.350)
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Main relief valve - Adjust - 580N Backhoe relief Pilot Controls only
Prior operation:
Main relief valve - Pressure test - Load Sense Relief Valve for 580N Backhoe relief Pilot Controls only (35.350).
The Load Sense Relief for the 580N Pilot is located in the
inlet section of the backhoe valve under the rear floor plate
of the cab.
1. Remove locking cover from load sense relief valve.
2. Loosen lock nut (1) located on adjustment screw (2).
RCIL10TLB001CAN 1
3. Turn adjustment screw clockwise to increase pres-

sure or counterclockwise to decrease pressure.
4. Check pressure. When pressure is in specification,
tighten adjustment screw lock nut. Install locking
cover.
Next operation:
Main relief valve - Replace - Load Sense Relief Valve (35.350).
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Main relief valve - Adjust Dual Stage Relief Valve, 580N Pilot
Controlled Backhoe Valves
The Dual Stage Relief valve is in the inlet section of the
loader control valve.
1. Loosen lock nut (1) located on adjustment flats(2).
RCPH10TLB010BAM 1
2. Turn adjustment screw clockwise to increase pres-

sure or counterclockwise to decrease pressure.
3. Check pressure. When pressure is in specification,
tighten adjustment screw lock nut. Install locking
cover.
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Main relief valve - Replace - Load Sense Relief Valve

Prior operation:
Main relief valve - Adjust - 580N Backhoe relief Pilot Controls only (35.350).
1. Loosen and remove load sense relief valve.

2. Lubricate load sense relief valve O-rings with clean
oil.
3. Install load sense relief valve in section bore.
4. Torque valve to 41 - 50 N·m (30.2 - 36.9 lb ft).
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Index

Main relief valve - Adjust - 580N Backhoe relief Pilot Controls only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Main relief valve - Adjust Dual Stage Relief Valve, 580N Pilot Controlled Backhoe Valves . . . . . . . . . . . . . . . . . . . 16
Main relief valve - Adjust Main Relief Valve, 580N with mechanical controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Main relief valve - Cleaning Relief Valve, Backhoe Main Relief Valve, 580N with Pilot Backhoe Controls . . . . . . 12
Main relief valve - Drawing Load Sense Relief Valve, 580N with Pilot Controlled Backhoe . . . . . . . . . . . . . . . . . . . . 8
Main relief valve - Drawing Relief Valve, 4000 psi Spike Clipper for Loader Valve on 580SN, 580SN WT and 590SN
machines with mechanical backhoe controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Main relief valve - Drawing Relief Valve, Loader Dump, Backhoe Swing on mechanically controlled Backhoes . . 4
Main relief valve - Drawing Relief Valve, Main System Dual Stage for 580N with Pilot Controlled Backhoe . . . . . 7
Main relief valve - Drawing Single Stage Relief Valve, 580 Main Relief with mechanical backhoe controls . . . . . . 6
Main relief valve - Drawing Swing and Bi-Dir Aux section, Backhoe Control Valves for 580N, 580SN, 580SN WT
and 590SN Pilot Controlled Machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Main relief valve - Pressure test - Load Sense Relief Valve for 580N Backhoe relief Pilot Controls only . . . . . . . 14
Main relief valve - Pressure test Loader and Backhoe Main Relief Valve for 580N mechanical machines only. Loader
Main Relief Valve for 580N machine with Pilot Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Main relief valve - Remove - Circuit relief valve, 580N, 580SN, 580SN WT and 590SN machines with Pilot Controls
(Swing and Bi-Directional relief valves only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Main relief valve - Replace - Load Sense Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Main control valve - 359
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
Stacked control valves

Loader bucket - Torque - Special torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA

Loader bucket - Exploded view - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE

Loader bucket - Check - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Loader bucket - Remove - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Loader bucket - Install - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Hydraulic systems - Main control valve
Stacked control valves Loader bucket - Torque - Special torques

Relief valves, item numbers (1), (2), (3), (4), and (14) 65 N·m +/- 6.7 (48 lb ft +/- 5)
Check valves, item number (7) 122 N·m +/- 12 (90 lb ft +/- 9)
Anti void assembly, item number (6) 65 N·m +/- 6.7 (48 lb ft +/- 5)
End cap inner mounting bolts, item number (36) 65 N·m +/- 6.7 (48 lb ft +/- 5)
End cap outer mounting bolt, item number (18) 100 N·m +/- 10.8 (74 lb ft +/- 8)
Check valve assembly, item number (40) 65 N·m +/- 6.7 (48 lb ft +/- 5)
Center spring and seal retainer plate mounting screws, item numbers (32) and 9.4 N·m +/- 1.3 (7 lb ft +/- 1)
(37)
Centering spring retaining bolt, item number (46) 9.4 N·m +/- 1.3 (7 lb ft +/- 1)
RCPH10TLB057GAL 1
1. Relief valve 206.8 bar (3000 psi) 11. Stabilizer spool 21. Dipper B port
2. Relief valve 331 bar (4800 psi) 12. Dipper spool 22. Bucket B port
3. Relief valve 237.8 bar (3450 psi) 13. Bucket spool 23. Extend-A-Hoe B port
4. Relief valve 221 bar (3205 psi) 14. Relief valve 3800 psi 24. Auxiliary hydraulics B port
5. Plug assembly 15. Extend-A-Hoe spool 25. Swing A port
6. Anti void assembly 16. Auxiliary hydraulics section 26. Boom A port
7. Check valve 17. End cap 27. Dipper A port
8. Swing spool 18. End cap outer mounting bolt 28. Bucket A port
9. Boom spool 19. Swing B port 29. Extend-A-Hoe A port
10. Stabilizer spool 20. Boom B port 30. Auxiliary hydraulics A port
NOTE: Relief valves are preset and have a tolerance of 2.4 bar +/- (35 psi +/- )
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Stacked control valves Loader bucket - Exploded view - Mechanical

linkage backhoe machines only
RCPH10TLB058GAL 1
31. Inlet port 34. Right stabilizer A port 37. Spool end cap retainer screws
32. Spool seal retainer plate screws 35. Outlet port 38. Left stabilizer B port
33. Left stabilizer A port 36. End cap inner mounting bolts 39. Right stabilizer B port
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RCPH10TLB008FAL 1
40. Low leak valve assembly 43. Lower spool seal 46. Centering spring retaining bolt
41. Upper spool seal 44. Seal retainer plate 47. Spool end cap
42. Seal retainer plate 45. Centering spring
NOTE: The low leak valves (40) are only in the boom and dipper sections.
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RCPH10TLB059GAL 1
Valve cut away view
RCPH10TLB007FAL 2
Valve schematic
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RCPH10TLB009FAL 1
Circuit relief valve
1. Poppet 6. Back-up ring 11. Back-up ring

2. Sleeve 7. O-ring 12. Shim 0.127 cm (0.050 in)
3. O-ring 8. Spring 13. Shim 0.0508 cm (0.020 in)
4. Spring 9. Retaining ring 14. Shim 0.0177 cm (0.007 in)
5. Screw 10. O-ring 15. Shim 0.0127 cm (0.0050 in)
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Stacked control valves Loader bucket - Check - Mechanical linkage

backhoe machines only
Pressure relief valves
1. Remove valve from valve body.
2. Lubricate O-ring with hydraulic oil.
3. Install valve and torque to 65 N·m +/- 6.7 (48 lb ft +/-
5)
Spool valve seals

1. Disconnect the linkage from the spool to be removed.
2. Remove the spool end cap retainer screws (37),
spool end cap (47), and seal retaining plate (44).
3. Remove the spool from the valve body.
4. Remove the spool seal retainer plate mounting
screws (32), spool seal retainer plate (42), and spool
seal (41).
5. Remove the spool centering spring retaining bolt (46)
and centering spring with caps (45) from the spool.
6. Clean and inspect spool and spool bore for scoring
or scratches, repair or replace as necessary.
7. Lubricate the spool with clean hydraulic oil, install the
spool in the valve body.
8. Install the lower spool seal (43) and seal retainer
plate (44).
NOTICE: When replacing spool seals, place spool in section, insert seal into section. Do not place seal in first and
install spool, this will damage the seal.
9. Install the centering spring with caps (45), centering
spring retaining bolt and torque to 9.4 N·m +/- 1.3 (7
lb ft +/- 1)
10. Install the spool end cap (47), spool end cap retaining
screws (37) and torque to 9.4 N·m +/- 1.3 (7 lb ft +/-
1)
11. Install the upper seal (41), upper seal retaining plate
(42) and torque to 9.4 N·m +/- 1.3 (7 lb ft +/- 1)
12. Connect linkage to the spool.
Check valves
1. Remove the check valve (7).
NOTE: Make sure all components of check valve come
out of the valve body, see cutaway view. Stacked control
valves Loader bucket - Exploded view (35.359)
2. Lubricate O-ring with hydraulic oil.
3. Install check valve (7) and torque to 122 N·m +/- 12
(90 lb ft +/- 9)
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End cap and auxiliary hydraulics section

1. Remove end cap mounting bolts (18) and (36), re-
move end cap (17), and if equipped auxiliary hy-
draulic section (16).
2. Replace all O-rings.
3. Place bolts through end cap (17) and if equipped aux-
iliary hydraulic section (16).
4. Install bolts into main valve body and torque outer
bolts (18) to 100 N·m +/- 10.8 (74 lb ft +/- 8) and
inner bolts (36) to 65 N·m +/- 6.7 (48 lb ft +/- 5).
Low leak valve

1. Remove the low leak valve (40).
NOTE: Make sure all components of low leak valve come
out of the valve body, see cutaway view. Stacked control
valves Loader bucket - Exploded view (35.359)
2. Lubricate O-rings with hydraulic oil.
3. Install low leak valve (40) and torque to 65 N·m +/-
6.7 (48 lb ft +/- 5).
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Stacked control valves Loader bucket - Remove - Mechanical

NOTICE: Do not remove more than one spool at a time from the valve body.
1. Clean the valve body.
2. If equipped, remove the cap screws from the auxiliary
section centering spring cover.
RCPH10TLB102ABL 1
3. Remove the centering spring cover.
RCPH10TLB103ABL 2
4. Remove the spool from the section.
RCPH10TLB105ABL 3
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5. Loosen the plug.
RCPH10TLB107ABL 4
6. Remove the plug from the valve section.
RCPH10TLB108ABL 5
7. Loosen the end cap bolts.
RCPH10TLB110ABL 6
8. Remove the end cap and if equipped, auxiliary sec-

tion.
RCPH10TLB111ABL 7
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9. Lay the end cap and auxiliary section on to the

bench, remove the bolts.
NOTE: Make a note of the size and location of the bolts.
RCPH10TLB112ABL 8
10. Remove the end cover from the auxiliary section.
RCPH10TLB113ABL 9
RCPH10TLB114ABL 10
RCPH10TLB115ABL 11
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13. Remove the seal retaining plate, remove and discard

seal and wiper.
RCPH10TLB117ABL 12
14. Number the valve body and the components.

NOTE: The relief valves are set at different pressures and
must be placed back in the same location from which they
were removed.
RCPH10TLB121ABL 13
15. Loosen the relief valve.
RCPH10TLB123ABL 14
16. Remove the relief valve from the valve body.
RCPH10TLB124ABL 15
17. Repeat steps 15 and 16 for the remaining relief

valves.
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18. If equipped, loosen the plug from the extend-a-hoe

section.
RCPH10TLB126ABL 16
19. Remove the plug from the valve body.
RCPH10TLB127ABL 17
20. Repeat steps 15 though 19 for the other side of the

valve body.
21. Make sure to mark the centering spring covers with
identification numbers.
RCPH10TLB128ABL 18
22. Loosen the cap screws for the centering spring cover.
RCPH10TLB130ABL 19
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23. Remove the centering spring cover.
RCPH10TLB131ABL 20
24. Repeat steps 22 and 23 for the remaining centering

spring covers.
25. Note any color coding on the centering springs.
RCPH10TLB132ABL 21
26. Make a note on the valve body of the color of the

spring.
RCPH10TLB133ABL 22
RCPH10TLB134ABL 23
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28. Remove the seal from the spool.
RCPH10TLB138ABL 24
29. Remove the wipe seal from the spool.
RCPH10TLB137ABL 25
30. Remove the seal retaining plate.
RCPH10TLB136ABL 26
31. Remove the spool end.
RCPH10TLB141ABL 27
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32. Reassemble the spool and insert back into the valve
body, make sure the wiper seal faces out towards the
retainer plate.
RCPH10TLB142ABL 28
RCPH10TLB135ABL 29
34. Remove the O-ring from the spacer.
RCPH10TLB140ABL 30
35. Remove the spacer from the spool.
RCPH10TLB139ABL 31
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36. Remove the seal from the spool.
RCPH10TLB138ABL 32
37. Remove the wipe seal from the spool.
RCPH10TLB137ABL 33
RCPH10TLB136ABL 34
39. Reassemble the spool and insert back into the valve
body, make sure the wiper seal faces out towards the
retainer plate.
RCPH10TLB142ABL 35
40. Repeat steps 27 though 39 for the remaining spools.
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41. Remove the cap screws for the seal retaining plate.
RCPH10TLB143ABL 36
RCPH10TLB144ABL 37
43. Remove the wiper seal.
RCPH10TLB145ABL 38
44. Remove the spool seal.
RCPH10TLB146ABL 39
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Stacked control valves Loader bucket - Install - Mechanical linkage

backhoe machines only
Prior operation:
Stacked control valves Loader bucket - Remove (35.359)
1. Install a new spool seal.
RCPH10TLB147ABL 1
2. Install a new wiper seal.
RCPH10TLB148ABL 2
NOTE: Make sure the lip of the wiper seal is facing out towards the seal retaining plate.
3. Install the seal retaining plate.
RCPH10TLB144ABL 3
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4. Install seal retaining plate cap screws and torque to

9.4 N·m +/- 1.3 (7 lb ft +/- 1)
RCPH10TLB074ABL 4
5. Repeat steps 41 through 48 for the remaining spool

seals.Loosen and remove the check valve.
RCPH10TLB075ABL 5
6. Install the check valve and spring into the valve body,
replace the O-ring on the plug. Hand tighten the plug
into the valve body making sure not to bind the valve.
RCPH10TLB076ABL 6
7. Torque the check valve to 122 N·m +/- 12 (90 lb ft

+/- 9)
RCPH10TLB149ABL 7
8. Repeat steps 5 to 7 for the remaining check valves.
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9. Loosen the anti void plug.
RCPH10TLB159ABL 8
10. Replace the O-rings and backup ring on the anti void
valve and plug.
RCPH10TLB157ABL 9
11. Install and hand tighten the plug into the valve body
making sure not to bind the valve.
RCPH10TLB160ABL 10
12. Torque the anti void to 65 N·m +/- 6.7 (48 lb ft +/- 5)
RCPH10TLB158ABL 11
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13. Loosen the plug for the check valve.
RCPH10TLB150ABL 12
14. Remove the plug, spacer, spring, and valve from the
valve body.
RCPH10TLB152ABL 13
15. Install the valve.
RCPH10TLB153ABL 14
RCPH10TLB154ABL 15
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RCPH10TLB155ABL 16
18. Make sure the washer is seated flat on the spring.
RCPH10TLB156ABL 17
19. Install a new O-ring on the plug, install the plug and
torque to 65 N·m +/- 6.7 (48 lb ft +/- 5)
RCPH10TLB151ABL 18
20. Install centering spring covers and torque to 9.4 N·m

+/- 1.3 (7 lb ft +/- 1)
RCPH10TLB130ABL 19
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21. Install a new O-ring on the plug and torque to 65 N·m

+/- 6.7 (48 lb ft +/- 5)
RCPH10TLB126ABL 20
22. Install new O-rings on relief valves and torque to 65

N·m +/- 6.7 (48 lb ft +/- 5)
RCPH10TLB123ABL 21
RCPH10TLB120ABL 22
24. Install a new spool seal and wiper seal.
RCPH10TLB119ABL 23
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25. Install the seal retaining plate and cap screws.

Torque cap screws to 9.4 N·m +/- 1.3 (7 lb ft +/- 1)
RCPH10TLB117ABL 24
26. Replace the O-ring.
RCPH10TLB116ABL 25
27. Install the valve.
RCPH10TLB115ABL 26
RCPH10TLB114ABL 27
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29. Place the end cap on the auxiliary section.
RCPH10TLB113ABL 28
30. Set the bolts through the end cover into the auxiliary
section.
NOTE: The larger of the three bolts goes into the top hole.
RCPH10TLB112ABL 29
31. Pull the end cap and auxiliary section up evenly,

torque the end cover bolts to 100 N·m +/- 10.8 (74
lb ft +/- 8)
RCPH10TLB110ABL 30
32. Install a new O-ring on the plug.
RCPH10TLB108ABL 31
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33. Install and torque the plug to 65 N·m +/- 6.7 (48 lb ft
+/- 5).
RCPH10TLB107ABL 32
34. Install the spool in the valve body.
RCPH10TLB105ABL 33
35. Install the centering spring cover.
RCPH10TLB103ABL 34
36. Install and torque the cap screws to 9.4 N·m +/- 1.3
(7 lb ft +/- 1)
RCPH10TLB102ABL 35
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Index

Stacked control valves Loader bucket - Check - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . . 8
Stacked control valves Loader bucket - Exploded view - Mechanical linkage backhoe machines only . . . . . . . . . . 4
Stacked control valves Loader bucket - Install - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . . . 20
Stacked control valves Loader bucket - Remove - Mechanical linkage backhoe machines only . . . . . . . . . . . . . . 10
Stacked control valves Loader bucket - Torque - Special torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Auxiliary hydraulic valves and lines - 525
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Quick coupling
Exploded view - Extendahoe hose routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view - Coupler hose routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Exploded view - Coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Exploded view - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sectional view Backhoe and Loader Quick Coupler Single Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Sectional view Backhoe and Loader Quick Coupler Dual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE
Remote valve
Disassemble - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspect - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assemble - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Check - Swing Cushion Valve (Swing Drift Troubleshooting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Quick coupling
Remove - Hydraulic backhoe quick coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Install - Hydraulic backhoe quick coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Disassemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Inspect - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Assemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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Hydraulic systems - Auxiliary hydraulic valves and lines
Quick coupling - Exploded view - Extendahoe hose routing
RCPH10TLB012GAM 1
580SN, 590SN WT and 590 SN Extendahoe hose routing
(1) Cylinder Assembly, bucket (7) Clamp

(2) Cylinder Extendahoe (8) Elbow, 45° adjustable
(3) Tube, Bucket Cylinder Rod (9) Elbow, 90° adjustable
(4) Tube, Bucket Cylinder Head (10) Connector 5/8 ORFS-ORB 5/8
(5) Tube, Extendahoe Cylinder Rod (11) Support
(6) Tube, Bucket Cylinder Rod
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Quick coupling - Exploded view - Coupler hose routing

(1) 5 mm (0.20 in) Clearance (minimum) (3) 90 ° Elbows
(2) Hoses (4) Coupler
RCPH10TLB002AAL 1
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Quick coupling - Exploded view

(1) Coupler
(2) Fitting access hole
RCPH10TLB018AAL 1
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Quick coupling - Exploded view - Coupler cylinder
RCPH10TLB006FAL 1
(1) Cylinder tube (5) Internal retaining ring

(2) Retaining ring (6) Spacer
(3) Rod (7) External retaining ring
(4) Gland
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Quick coupling - Exploded view - Quick coupler cylinder
RCPH10TLB006FAL 1
Quick coupler cylinder
(1) Tube (4) Snap ring

(2) Snap ring (5) Gland
(3) Spacer
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RCPH10TLB003FAL 2
Coupler cylinder piston
(6) Piston rod (9) Ring

(7) Seal (10) O-ring
(8) Ring
RCPH10TLB020AAL 3
Coupler cylinder gland
(11) Wiper seal (14) O-ring

(12) Bushing (15) Backup ring
(13) Seal
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Quick coupling - Exploded view - Swing dampening valve
RCPH10TLB002FAL 1
(1) Swing cushion valve (7) Plug

(2) Inline check valve (8) Bi-directional check valve
(3) Orifice check valve (9) Crossover spool assembly
(4) Bi-directional check valve (10) Plug
(5) Internal inline check valve (11) Spring
(6) Orifice plug (12) Crossover spool
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Quick coupling - Sectional view Backhoe and Loader Quick Coupler

Single Valve
RCPH10TLB006CAM 1
(1) A Port - To RETRACT side of cylinder (6) Load Sensing Port

(2) B Port - To EXTEND side of cylinder (7) Two position - 2 way solenoid valve to
control pilot pressure
(3) Pressure Relief Valve (8) Two position - 4 way solenoid valve to
control cylinder
(4) To Tank (9) Orifice and check valve
(5) Pressure Port
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Quick coupling - Sectional view Backhoe and Loader Quick Coupler

Dual Valve
RCPH10TLB002HAM 1
(1) A Port - To RETRACT side of cylinder (6) Load sensing port

(2) B Port - To EXTEND side of cylinder (7) Two position - 2 way solenoid valve to
control pilot pressure
(3) Pressure relief valve (8) Two position - 4 way solenoid to control
cylinder
(4) To tank (9) Orifice and check valve
(5) Pressure Port
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Remote valve - Disassemble - Swing dampening valve

NOTE: Your valve may appear different than that of the following photos, the procedures are the same.
1. Fasten the swing cushion valve in the vise with soft
jaws. Loosen the plug for the crossover spool as-
sembly.
RCPH10TLB003AAL 1
2. Remove the plug.
RCPH10TLB004AAL 2
RCPH10TLB005AAL 3
4. Remove the crossover spool.
RCPH10TLB006AAL 4
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5. Loosen and remove the inline check valve.
RCPH10TLB007AAL 5
6. Loosen and remove the internal inline check valve.
RCPH10TLB008AAL 6
7. Loosen and remove the orifice check valve.
RCPH10TLB009AAL 7
8. Loosen and remove the orifice plug.
RCPH10TLB010AAL 8

swing cushion valve.
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10. Loosen and remove the plug for the bi-directional

check valve.
RCPH10TLB011AAL 9
11. Loosen and remove the bi-directional check valve.
RCPH10TLB012AAL 10
Next operation:
Remote valve - Inspect (35.525)
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Remote valve - Inspect - Swing dampening valve

Prior operation:
Remote valve - Disassemble (35.525)
1. Inspect the parts of the crossover spool assembly.

Replace the O-ring (2) on the plug. Replace parts as
required.
RCPH10TLB016AAL 1
1. Plug 3. Spring
2. O-ring 4. Crossover spool
2. Inspect the parts of the inline check valve (1) and

internal inline check valve (4). Replace the O-rings
(2) and backup ring (3). Use new parts as required.
RCPH10TLB014AAL 2
3. Inspect the parts of the orifice check valve (1) and

orifice plug (4). Replace the O-rings (2) and backup
ring (3). Use new parts as required.
RCPH10TLB015AAL 3
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4. Inspect the parts of the bi-directional check valve (1)

and plug (4). Replace the O-rings (2) and backup
rings (3). Use new parts as required.
RCPH10TLB013AAL 4
Next operation:
Remote valve - Assemble (35.525)
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Remote valve - Assemble - Swing dampening valve

Prior operation:
Remote valve - Inspect (35.525)
1. Use clean oil to lubricate the O-rings (2) and backup

rings (3) on the bi-directional check valve (1) and plug
(4).
RCPH10TLB013AAL 1
2. Install the bi-directional check valve. Tighten the

bi-directional check valve to a torque of 5.4 - 6.7 N·m
(48 - 59 lb in).
RCPH10TLB012AAL 2
3. Install the plug for the bi-directional check valve.

Tighten the plug to a torque of 15 - 20 N·m (133 -
177 lb in).
RCPH10TLB011AAL 3

rings (3) on the orifice check valve (1) and orifice plug
(4).
RCPH10TLB015AAL 4
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5. Install the orifice plug. Tighten the orifice plug to a

torque of 8 - 11 N·m (71 - 97 lb in).
RCPH10TLB010AAL 5
6. Install the orifice plug. Tighten the orifice plug to a

torque of 29 - 33 N·m (257 - 292 lb in).
RCPH10TLB009AAL 6

rings (3) on the inline check valve (1) and internal
inline check valve (4).
RCPH10TLB014AAL 7
8. Install the internal inline check valve. Tighten the

internal inline check valve to a torque of 10 - 13 N·m
(89 - 115 lb in).
RCPH10TLB008AAL 8
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9. Install the inline check valve. Tighten the inline check

valve to a torque of 29 - 33 N·m (257 - 292 lb in).
RCPH10TLB009AAL 9

section.
11. Use clean oil to lubricate the O-ring (2) on the plug
(1), the spring (3), and the crossover spool (4).
RCPH10TLB016AAL 10
12. Install the crossover spool.
RCPH10TLB006AAL 11
RCPH10TLB005AAL 12
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14. Start the plug into the valve.
RCPH10TLB004AAL 13
15. Tighten the plug to a torque of 25 - 30 N·m (221 - 266

lb in).
RCPH10TLB003AAL 14
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Remote valve - Check - Swing Cushion Valve (Swing Drift

Troubleshooting)
1. Park machine on firm and level surface.
2. Ensure hydraulic oil is at operating temperature of 52
°C (125.6 °F).
3. Position loader bucket flat on ground. Lower stabi-
lizers to position rear tires 152.4 mm (6 in) above
ground.
4. Move backhoe from transport position. Fully extend
dipper and bucket. Lower boom until backhoe bucket
is 304.8 mm (12 in) above ground.
NOTE: If equipped with extend-a-hoe option, ensure feature is completely retracted.

5. Use a stabilizer to lower one side of machine. Lower
until rear tire achieves minimal contact to ground.
6. Measure angle of backhoe frame. Raise or lower sta-
bilizers to ensure machine is positioned at 10 degree
angle from level side to lowered side.
7. Lower boom and position backhoe bucket on ground.
Mark ground location of backhoe bucket.
8. Raise boom and position backhoe bucket 1.8 m (6
ft) above ground.
9. Turn engine OFF. Wait five minutes.
10. Start engine. Lower boom and establish minimal
ground contact with backhoe bucket.
11. Measure distance between current location and
marked location as determined in step 7. Record
result.
NOTE: Result should not exceed 203.2 mm (8 in).
12. Repeat previous steps to measure swing drift for
other side of machine.
13. Do the following for measured results:
• If swing drift exceeds 203.2 mm (8 in) for both
sides, see Swing Drift Measured in Two Direc-
tions for procedures.
• If swing drift exceeds 203.2 mm (8 in) on one
side only, see Swing Drift Measured in One
Direction for procedures.
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Swing Drift Measured in Two Directions

1. Remove hoses from swing cushion valve fittings. In-
stall caps and plugs for open hoses and fittings.
2. Repeat steps 1 through 12.
• If swing drift is noted, swing cylinders are sus-
pect. Repair swing cylinders as required. See
Swing cylinder - Disassemble - Swing cylin-
ders (all models) (35.739) for procedure.
• If swing drift is not present, continue to the next
step.
3. Remove swing cushion valve.
4. Connect swing hoses to swing sections located in
backhoe control valve.
• If swing drift is noted, swing section of backhoe
control valve is suspect. Inspect and repair as
required.
• If swing drift is not present, swing cushion valve
is suspect. Replace swing cushion valve. See
Remote valve - Inspect - Swing dampening
valve (35.525) for procedure.
Swing Drift Measured in One Direction

1. Disconnect swing cushion valve from swing section
in backhoe control valve.
2. Connect hoses to swing section in backhoe control
valve.
• If swing drift is not present, swing cushion valve
is suspect. Replace swing cushion valve. See
Remote valve - Inspect - Swing dampening
valve (35.525) for procedure.
• If swing drift is noted, continue to the next step.
4. Inspect anti-cavitation check valve located in swing
valve. Replace as required.
5. Inspect swing circuit relief valve O-ring, located in
swing valve section. Replace as required.
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Quick coupling - Remove - Hydraulic backhoe quick coupler

NOTE: Refer to Quick coupling - Exploded view (35.525)
1. Remove the bucket from the backhoe.
2. Remove the retaining rings (1) from the sleeves (11)
and (23).
3. Extend the piston rods out.
4. Remove the groove pins (2) from the step pins (3).
5. Remove the step pins (3).
NOTE: Step pins can be difficult to remove, due to the fit
of the step pin seal (14).
NOTE: If the cylinder (10) needs to be removed or the tube
is damaged follow steps 6 through 12. If only the piston
seals are to be replaced go to Quick coupling - Disas-
semble (35.525).
6. Remove the two bolts (19) and two washers (20)
which fasten the cover (18) to the hose guard (6).
7. Remove and discard the two countersunk head
socket screws (17) that fasten the hose guard (6) to
the coupler (15) and retain the cylinder (10) in place.
8. Remove and discard the two outer set screws (4) and
two outer set screws (5) that fasten the sleeves (11)
and (23) in place.
9. Disconnect the hoses (7) from the 90 ° elbows (8)
and plug the hoses.
10. Remove the 90 ° elbows (8) and the adapters (9)
from the cylinder (10).
NOTE: Adapters (9) are sealed in place with silicone sealant.

11. Use an acceptable driver being capable of 178 - 222
kN (40016 - 49908 lb) and drive the cylinder tube
(10) and the sleeve (11) out of the coupler (15).
12. Drive the other sleeve (23) out of the coupler (15).
Next operation:
Quick coupling - Install (35.525)
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Quick coupling - Install - Hydraulic backhoe quick coupler

Prior operation:
Quick coupling - Remove (35.525)
1. Center the coupler (15) between the dipper ears (24).

2. Install the sleeve (23) with the groove for the outer
coupler set screws (4) and (5) towards the center of
the coupler (15).
kN (40000 - 50000 lb) and drive the sleeve (23) into
the coupler (15) until the groove is in the center of
the set screw (4) and (5) holes.
4. Align the two slots in the cylinder tube (10) with the
two tapped holes in the center of the coupler (15).
Make sure the hydraulic ports (12) and (13) in the
cylinder tube (10) line up with the openings in the
coupler (15). The smaller hydraulic port (12) should
be towards the top of the coupler (15).
5. Install the cylinder (10), as indicated on illustration
Quick coupling - Exploded view (35.525), so that
the smaller hydraulic port (12) is towards the top of
the coupler (15) and the cylinder (10) it is up against
the sleeve (23). Drive the sleeve (23) in or out, so
that the hydraulic ports (12) and (13) are in the center
of the opening in the coupler (15).
6. Use new screws, install two outer coupler set screws
(4) and (5) to hold the sleeve (23) in place. Tighten
the outer coupler set screws to a torque of 14 - 20
N·m (124 - 177 lb in).
7. Install the other sleeve (11) with the grooves for the
outer coupler set screws (4) and (5) towards the cen-
ter of the coupler (15).
kN (40000 - 50000 lb) and drive the other sleeve (11)
into place until it contacts the cylinder (10).
9. Use new screws, install two outer coupler set screws
(4) and (5) to hold the sleeve (11) in place. Tighten
the outer coupler set screws to a torque of 14 - 20
N·m (124 - 177 lb in).
10. Place the step pin seal (14) in the groove on the
outside of each of the step pins (3). See step pin seal
orientation (16) for proper step pin seal installation.
11. Lubricate the outside diameters of both step pins (3)
with Lubriplate prior to installation.
12. With the piston rods extended out, install the step
pins (3) and push the step pins (3) into place.
13. Align the hole for the groove pin (2) in the step pins
(3) with the hole in the piston rod and install the
groove pins (2). The groove pins (2) should be in-
stalled at least 2 mm (0.08 in) below the surface of
the step pins (3) on each side.
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14. Push the step pins (3) inward enough to allow the re-
taining rings (1) to be installed on the inside retaining
ring groove of the sleeves (11) and (23). Install the
retaining rings (1) in the sleeves (11) and (23).
15. Install the hoses (7) for the 580SN with the standard
dipper so that the hex on the fittings nearest to the
bucket pivot touches the clamp (27). Tighten the
clamp (27).
16. For the hose (7) installation on the 580SN and 590SN
machines equipped with the Extendahoe option, see
Quick coupling - Exploded view (35.525). Install
the hoses (7) on each side so that the hex on the fit-
tings nearest to the bucket pivot touches the isolator
(2). Tighten the clamps (1).
17. Install and tighten the two adapters (9) into the proper
hydraulic ports (12) and (13). Install the two 90 °
elbows (8) on the adapters (9).
18. Install the hoses (7) around the coupler (15) as
shown on Quick coupling - Exploded view
(35.525).
19. Refer to Quick coupling - Exploded view (35.525)
and connect the hoses (7) to the 90 ° elbows (8)
so that the hoses (7) are staggered to run on each
side of the coupler (15). Tighten the 90 ° elbows
(8) so that there is a minimum of 5 mm (0.20 in) of
clearance between the hoses (7) and each side of
the coupler (15). Tighten the hose connections on
the 90 ° elbows (8).
20. Place a 6 mm (0.24 in) fillet bead of RTV silicone
sealant around the inside of the coupler (15) fitting
access slot and area around the adapters (9). The
RTV silicone sealant should not prevent access to
the fittings in the coupler (15). Fill the ends of the set
screw holes (4) and (5) with RTV silicone sealant.
21. See the Quick coupling - Exploded view (35.525)
and route the hoses (7) for the proper machine ap-
plication (21) and (22) under the clamp (25).
22. Place 25 mm +/- 10 mm (0.98 in +/- 0.40 in) of the
cordura sleeve (26) under the clamp (25).
23. Install the hose guard (6) and cover (18) on the
coupler (15). Install and tighten the bolt (19) and
washer (20). Install two new countersunk head
socket screws (17) which fasten the hose guard
(6) to the coupler (15). The two countersunk head
socket screws (17) protrude into the grooves on the
cylinder tube (10) to hold the cylinder tube (10) in
place within the coupler (15). Tighten the two flat
head socket screws (17).
24. Start the engine and check for hydraulic leaks. Ro-
tate the coupler (15) at slow speed all the way back
to the bucket dump position. Stop the engine. Make
sure all the slack in the hoses (7) is taken up towards
the clamp (25). Tighten the clamp (25).
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Quick coupling - Disassemble - Quick coupler cylinder

NOTE: Refer to illustrations in Quick coupling - Exploded view (35.525).
1. Remove the bucket from the backhoe.
2. Remove the retaining rings (1) from the sleeves (11)
and (23).
3. Extend the piston rods out.
4. Remove the groove pins (2) from the step pins (3).
5. Remove the step pins (3).
NOTE: Step pins can be difficult to remove, due to the fit
of the step pin seal (14).
6. Remove the snap ring (2) from the gland (5). Then
push the gland (5) slightly into the cylinder.
7. Remove the spacer (3).
8. Remove the snap ring (4) from the tube (1).
9. Install the plastic service ring into the snap ring
groove in the tube (1).
RCPH10TLB019AAL 1
10. Pull the rod assembly (6) out of the tube (1).
11. Remove the plastic service ring from the tube (1).
12. Remove the gland (5) from the rod (6).
13. Fasten the rod (6) in a vise with soft jaws.
14. Remove the seal (7), ring (8), ring (9), and O-ring
15. Remove the wiper seal (11), bushing (12), seal (13),
O-ring (14), and backup ring (15) from the gland (5).
NOTE: Repeat steps 6 through 15 for the other side.
Next operation:
Quick coupling - Inspect (35.525)
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Quick coupling - Inspect - Quick coupler cylinder

Prior operation:
Quick coupling - Disassemble (35.525)
1. Clean the glands (5), piston rods (6) and tube (1) in
cleaning solvent.
2. Discard the parts that were removed from the pistons
and the glands (5).
3. Illuminate the inside of the tube (1). Inspect the in-
side of the tube (1) for deep grooves and other dam-
age. If there is damage to the tube (1), a new tube
(1) must be used. See Quick coupling - Remove
(35.525) for removal of cylinder tube.
4. Remove small scratches on the inside of the tube (1)
with emery cloth of medium grit. Use the emery cloth
with a rotary motion.
5. Check to be sure that the piston rods (6) are straight.
If a piston rod (6) is not straight, install a new piston
rod (6).
Plastic service ring orientation.
RCPH10TLB019AAL 1
Next operation:
Quick coupling - Assemble (35.525)
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Quick coupling - Assemble - Quick coupler cylinder

1. Install a new O-ring (10), ring (9), ring (8), and seal
(7) on the piston.
RCPH10TLB003FAL 1
2. Lubricate the bore of the gland (5) with clean oil and
push the gland assembly onto the piston rod (6). The
wide end of the gland (5) should contact the piston.
NOTE: Repeat steps 1 and 2 for the other gland (5) and piston rod (6).
3. Lubricate the seals of the piston rod (6) and the gland
(5) with clean oil. Push the piston rod and gland sub-
assembly into the bore of the tube (1) far enough to
allow the installation of the snap ring (4). If neces-
sary, use a soft hammer to drive the piston rod (6)
and gland (5) into the tube (1).
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RCPH10TLB006FAL 2
4. Install the snap ring (4) in the tube (1).

5. Pull the rod (6) outwards until the gland (5) is seated
against the snap ring (4).
6. Install the spacer (3) on the gland (5).
7. Install the snap ring (2) on the gland (5).
NOTE: Repeat steps 3 through 7 for the other side.
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Index

Quick coupling - Assemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Quick coupling - Disassemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Quick coupling - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Quick coupling - Exploded view - Coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Quick coupling - Exploded view - Coupler hose routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Quick coupling - Exploded view - Extendahoe hose routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Quick coupling - Exploded view - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Quick coupling - Exploded view - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Quick coupling - Inspect - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Quick coupling - Install - Hydraulic backhoe quick coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Quick coupling - Remove - Hydraulic backhoe quick coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Quick coupling - Sectional view Backhoe and Loader Quick Coupler Dual Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Quick coupling - Sectional view Backhoe and Loader Quick Coupler Single Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remote valve - Assemble - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Remote valve - Check - Swing Cushion Valve (Swing Drift Troubleshooting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Remote valve - Disassemble - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Remote valve - Inspect - Swing dampening valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Stabilizer hydraulic system - 703
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
Stabilizer cylinder
Torque - Stabilizer cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Stabilizer cylinder
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 243 Stabilizer cylinder - Torque - Stabilizer cylinder 35.703 / 4
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Hydraulic systems - Stabilizer hydraulic system
Stabilizer cylinder - Torque - Stabilizer cylinder

Apply LOCTITE® 243 to the cylinder piston bolt.
580N and 580SN

Cylinder piston bolt 1600 - 1820 N·m (1180 - 1342 lb ft)
Cylinder gland 135 - 542 N·m (100 - 400 lb ft)
Cylinder lock screw 2.3 N·m (20 lb in)
580SN WT and 590SN

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Stabilizer cylinder - Exploded view

(A) Stabilizer cylinder assembly (9) Piston seal
(1) Cylinder tube (10) Backup ring
(2) Gland (11) Wear ring
(3) Wiper rod (12) Piston rod
(4) Rod and buffer seal (13) Bolt with hardened washer
(5) Rod bearing (14) Locking screw
(6) Static head seal (15) Lube fitting
(7) Piston (16) Plug
(8) Loader ring
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RCPH11TLB021HAN 1
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Index

Stabilizer cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Stabilizer cylinder - Torque - Stabilizer cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Front loader bucket hydraulic system - 723
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Loader bucket control cylinder

Exploded view - Typical cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view - Typical cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE
Loader bucket control cylinder

Remove Loader Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install Loader Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Remove Loader Cylinder and Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install - Loader Cylinder and Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inspect - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Assemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
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Hydraulic systems - Front loader bucket hydraulic system
Loader bucket control cylinder - Exploded view - Typical cylinder
RCPH10TLB060GAL 1
1. Tube 6. Piston rod 11. Wear ring 16. Buffer seal

2. Lock screw 7. Bolt 12. O-ring 17. Bushing
3. Gland 8. Hardened washer 13. Backup ring 18. Bushing
4. Piston 9. Seal 14. Wiper
5. Piston rod eye 10. Backup ring 15. Rod seal
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Loader bucket control cylinder - Exploded view - Typical cylinder
RCPH10TLB162ABL 1
RCPH10TLB161ABL 2
3. Gland 11. Wear ring 15. Rod seal

4. Piston 12. O-ring 16. Buffer seal
9. Seal 13. Backup ring 17. Bushing
10. Backup ring 14. Wiper
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Loader bucket control cylinder - Exploded view - Quick coupler

cylinder
RCPH10TLB010FAL 1
1. Tube 3. Spacer 5. Gland

2. Snap ring 4. Snap ring
Coupler cylinder piston
RCPH10TLB003FAL 2
6. Piston rod 9. Ring

7. Seal 10. O-ring
8. Ring
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Coupler cylinder gland

11. Wiper seal 13. Seal 15. Backup ring
12. Bushing 14. O-ring
RCPH10TLB020AAL 3
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Loader bucket control cylinder - Remove Loader Lift Cylinder

WARNING
Escaping fluid!
Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or
other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or per-
forming work on the hydraulic system. Before applying pressure, make sure all connections are tight
and all components are in good condition. Never use your hand to check for suspected leaks under
pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your
doctor immediately.
W0178A
RCPH11TLB158AAM 1
2. Raise and support the loader arms.
RCPH11TLB159AAM 2
3. Remove the hydraulic tube clamp.
RCPH11TLB160AAM 3
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4. Disconnect and cap the rod end hydraulic tube.
RCPH11TLB161AAM 4
5. Disconnect and cap the closed end hydraulic fittings.
RCPH11TLB162AAM 5
6. Remove the inner snap ring.
RCPH11TLB163AAM 6
7. Attach a suitable lifting device to the cylinder.
RCPH11TLB164AAM 7
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8. Remove pin.
RCPH11TLB165AAM 8
9. Remove snap ring and washer.
RCPH11TLB166AAM 9
10. Carefully lift and remove the cylinder from the ma-
chine.
RCPH11TLB164AAM 10
NOTE: Repeat for the opposite cylinder if needed.
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Loader bucket control cylinder - Install Loader Lift Cylinder

WARNING
Escaping fluid!
doctor immediately.
W0178A
1. Move the cylinder into place.
RCPH11TLB164AAM 1
2. Install the inner snap ring.
RCPH11TLB163AAM 2
3. Install the pin.

RCPH11TLB165AAM 3
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5. Install the inner snap ring.
RCPH11TLB163AAM 4
6. Connect the closed end hydraulic fittings.
RCPH11TLB162AAM 5
7. Connect the rod end hydraulic tube.
RCPH11TLB161AAM 6
8. Reinstall the hydraulic tube clamp.
RCPH11TLB160AAM 7
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9. Remove the supports from the loader arms.
RCPH11TLB159AAM 8
10. Remove lifting device.
RCPH11TLB158AAM 9
NOTE: Repeat for the opposite cylinder if needed.
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Loader bucket control cylinder - Remove Loader Cylinder and Link

WARNING
Escaping fluid!
doctor immediately.
W0178A
1. Attach a suitable lifting device and support the loader

arm.
RCPH11TLB167AAM 1
2. Remove the hardware securing the pin.
3. Remove pin.
RCPH11TLB170AAM 4
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4. Remove link.
RCPH11TLB171AAM 5
5. Remove tube clamp.
RCPH11TLB172AAM 6
6. Remove hydraulic tubes. Caps all open ports.
RCPH11TLB173AAM 7
7. Support cylinder.
RCPH11TLB174AAM 8
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8. Remove self leveling link.
RCPH11TLB175AAM 9
9. Remove pin securing hardware.
RCPH11TLB176AAM 10
10. Remove inner bell crank arm.
RCPH11TLB177AAM 11
11. Remove bucket cylinder rod end snap ring.
RCPH11TLB163AAM 12
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12. Remove pin.
RCPH11TLB178AAM 13
13. Remove bucket cylinder.
RCPH11TLB179AAM 14
NOTE: If needed, repeat operation on other side.
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Loader bucket control cylinder - Install - Loader Cylinder and Link

1. Move the bucket cylinder into place.
RCPH11TLB179AAM 1
2. Install the pin.
RCPH11TLB178AAM 2
3. Install the snap ring on the bucket cylinder rod end.
RCPH11TLB163AAM 3
4. Install the inner bell crank arm.
RCPH11TLB177AAM 4
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5. Install the pin securing hardware.
RCPH11TLB176AAM 5
6. Reconnect the self leveling link.
RCPH11TLB175AAM 6
7. Remove supports and reconnect hydraulic tubes.
RCPH11TLB173AAM 7
8. Install the tube clamp.
RCPH11TLB172AAM 8
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9. Reinstall the link.
RCPH11TLB171AAM 9
10. Install pin.
RCPH11TLB170AAM 10
11. Install the hardware securing the pin.
12. Remove lifting device and supports from the loader

arm.
RCPH11TLB167AAM 13
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Loader bucket control cylinder - Disassemble - Quick coupler

cylinder
NOTE: Refer to illustrations Loader bucket control cylinder - Disassemble (35.723).
1. Remove the snap ring (2) from the gland (5). Then
push the gland (5) slightly into the cylinder.
2. Remove the spacer (3).
3. Remove the snap ring (4) from the tube (1).
4. Install the plastic service ring into the snap ring
groove in the tube (1).
NOTICE: See illustration Loader bucket control cylinder

- Assemble (35.723) for orientation of the plastic service
ring.
5. Pull the rod assembly (6) out of the tube (1).
6. Remove the plastic service ring from the tube (1).
7. Remove the gland (5) from the rod (6).
8. Fasten the rod (6) in a vise with soft jaws.
9. Remove the seal (7), ring (8), ring (9), and O-ring
10. Remove the wiper seal (11), bushing (12), seal (13),
O-ring (14), and backup ring (15) from the gland (5).
11. Do steps 1 through 10 for the other side.
Next operation:
Loader bucket control cylinder - Inspect (35.723)
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Loader bucket control cylinder - Inspect - Quick coupler cylinder

Prior operation:
Loader bucket control cylinder - Disassemble - Quick coupler cylinder (35.723)
1. Clean the glands (5), piston rods (6) and tube (1) in
cleaning solvent.
2. Discard the parts that were removed from the pistons
and the glands (5).
age. If there is damage to the tube (1), a new tube
(1) must be used. See section 8001 for removal of
cylinder tube.
4. Remove small scratches on the inside of the tube (1)
with emery cloth of medium grit. Use the emery cloth
with a rotary motion.
5. Check to be sure that the piston rods (6) are straight.
If a piston rod (6) is not straight, install a new piston
rod (6).
Next operation:
Loader bucket control cylinder - Assemble - Quick coupler cylinder (35.723)
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Loader bucket control cylinder - Assemble - Quick coupler cylinder

Prior operation:
Loader bucket control cylinder - Inspect (35.723)
1. Install the wiper seal (11) in the gland (5). The lips
must be toward the small end of the gland (5).
2. Install the seal (13) and bushing (12) in the gland (5).
3. Install the backup ring (15) and O-ring (14) on the
outside of the gland (5).
4. Install a new O-ring (10), ring (9), ring (8), and seal
(7) on the piston.
5. Lubricate the bore of the gland (5) with clean oil and
push the gland assembly onto the piston rod (6). The
wide end of the gland (5) should contact the piston.
6. Do steps 1 through 5 for the other gland (5) and pis-
ton rod (6).
7. Lubricate the seals of the piston rod (6) and the gland
(5) with clean oil. Push the piston rod and gland
sub-assembly into the bore of the tube (1) far enough
to allow the installation of the snap ring (4). If nec-
essary, use a soft hammer to drive the piston rod (6)
and gland (5) into the tube (1).
8. Install the snap ring (4) in the tube (1).
9. Pull the rod (6) outwards until the gland (5) is seated
against the snap ring (4).
10. Install the spacer (3)on the gland (5).
11. Install the snap ring (2) on the gland (5).
12. Do steps 7 through 12 for the other side.
Plastic service ring orientation
RCPH10TLB019AAL 1
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Index

Loader bucket control cylinder - Assemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Loader bucket control cylinder - Disassemble - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Loader bucket control cylinder - Exploded view - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Loader bucket control cylinder - Exploded view - Typical cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Loader bucket control cylinder - Exploded view - Typical cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Loader bucket control cylinder - Inspect - Quick coupler cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Loader bucket control cylinder - Install - Loader Cylinder and Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Loader bucket control cylinder - Install Loader Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Loader bucket control cylinder - Remove Loader Cylinder and Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Loader bucket control cylinder - Remove Loader Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Excavator and backhoe hydraulic controls - 726
580N NA
580SN WT NA
580SN NA
590SN NA
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35.726 / 1
Contents
FUNCTIONAL DATA
Control valve lever

Exploded view - Backhoe controls with foot swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view - Backhoe controls with hand swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Exploded view - Backhoe auxiliary control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE
Control valve lever

Adjust - Adjustment of the backhoe control levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Hydraulic systems - Excavator and backhoe hydraulic controls
Control valve lever - Exploded view - Backhoe controls with foot

swing
RCPH10TLB095GAL 1
1. Extendahoe (if used) 7. RH stabilizer

2. Spacer (used without 8. LH swing pedal
extendahoe)
3. Boom 9. Swing control shaft
4. Dipper 10. RH swing pedal
5. Bucket 11. Shim washers. Use as necessary between the control levers to remove end play. Use
at least one shim washer (11) between each two control levers.
6. LH stabilizer 12. Clevis. Adjust so that the swing pedals (8) and (10) are at an angle of 19 - 20 ° from
the floor when the “J” lug on the swing bellcrank (9) is parallel to the floor.
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Control valve lever - Exploded view - Backhoe controls with hand

swing
RCPH10TLB096GAL 1
1. Bucket and dipper 7. RH stabilizer

2. Bucket 8. LH stabilizer
3. Dipper 9. Control lever mounting bracket
4. Boom and swing 10. Extendahoe control pedal (if equipped)
5. Boom 11. Extendahoe control pivot (mounted on RH side of backhoe
control tower)
6. Swing
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Control valve lever - Exploded view - Backhoe auxiliary control

RCPH10TLB046GAL 1
1. Control lever
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35.726 / 5
Control valve lever - Adjust - Adjustment of the backhoe control

levers
1. All control levers (1) must be in alignment and cen-

tered in the slots in the control tower (2). See the
illustration below.
2. All control levers (1) must be within 71 - 73 ° from the
floor plate as seen from the right side of the backhoe.
RCPH10TLB094GAL 1
(Right Side Shown)
1. Control levers 3. Floor plate

2. Control tower 4. 71 - 73 °
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Index

Control valve lever - Adjust - Adjustment of the backhoe control levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Control valve lever - Exploded view - Backhoe auxiliary control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control valve lever - Exploded view - Backhoe controls with foot swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Control valve lever - Exploded view - Backhoe controls with hand swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Boom hydraulic system - 736
580N
580SN WT
580SN
590SN
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35.736 / 1
Contents
TECHNICAL DATA
Boom cylinder
Torque - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Boom cylinder
Exploded view - Boom cylinder (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Boom cylinder
Remove - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Overhaul - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Assemble - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Boom relief valve
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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35.736 / 2
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 243 Boom cylinder - Assemble - Boom cylinder 35.736 / 12
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35.736 / 3
Hydraulic systems - Boom hydraulic system
Boom cylinder - Torque - Boom cylinder

580N, 580SN,and 580SN WT

590SN
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35.736 / 4
47365539 08/07/2012
35.736 / 5
Boom cylinder - Exploded view - Boom cylinder (all models)

Cylinder components are similar for all models, the difference being in the dimensions of the components.
(A) Boom cylinder assembly (9) Wear ring

(1) Cylinder tube (10) 4 piece piston seal assembly
(2) Gland (11) Piston rod
(3) Rod bearing (12) Internal bushing
(5) Static head seal (14) Locking screw
(6) Wiper rod (15) Lube fitting
(8) Cast iron ring
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RCPH11TLB019HAN 1
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Boom cylinder - Remove - Boom cylinder

Hydraulic fluid will be released during this procedure be prepared to direct the fluid into a suitable container and
dispose of properly.
1. Provide adequate support to the boom arm.
RCPH10TLB779AAD 1
RCPH10TLB586AAD 2
3. Disconnect and cap hydraulic tubes or hoses.
RCPH10TLB585AAD 3
4. Remove the snap ring and washer from the swing

tower to boom cylinder pin.
RCPH10TLB588AAD 4
47365539 08/07/2012
35.736 / 8
5. Remove the pin.
RCPH10TLB584AAD 5
6. Remove the snap ring and washer from the upper

boom cylinder pin.
RCPH10TLB589AAD 6
7. Remove the pin.

8. Remove the cylinder from the boom arm.
RCPH10TLB778AAD 7
Next operation:
Boom cylinder - Disassemble - Boom cylinder (35.736)
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Boom cylinder - Disassemble - Boom cylinder

Prior operation:
Boom cylinder - Remove - Boom cylinder (35.736)
NOTE: Refer to the Boom cylinder - Exploded view - Boom cylinder (all models) (35.736) illustration.
1. Clean the outside of cylinder using appropriate
cleaning solvent.
2. Secure tube (1) in a vise. Use care to prevent dam-
age to tube.
3. Loosen and remove lock screw (14) from gland (2)
and tube (1).
4. Use gland wrench to loosen and remove the gland
(2) from tube (1).
5. Remove piston rod (11) from tube (1). Ensure piston
rod is removed straightly to prevent damage to tube.
6. Secure piston rod (11) eye in vise. Place a support
below piston rod eye, near piston (7). To prevent
damage, place shop cloth between support and pis-
ton rod.
7. Remove bolt with hardened washer (13). Use torque
multiplier tool for bolts having high torque value.
8. Remove piston (7) from piston rod (11).
9. Remove gland (2) from piston rod (11).
10. Remove four piece piston seal assembly (10), wear
ring (9), and cast iron ring (8) from piston (7).
11. Remove static head seal (5), rod bearing (3), rod and
buffer seal (4), and wiper rod (6) from gland (2).
Next operation:
Boom cylinder - Overhaul - Boom cylinder (35.736)
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Boom cylinder - Overhaul - Boom cylinder

Prior operation:
Boom cylinder - Disassemble (35.736)
1. Clean piston (7), gland (2), piston rod (11), tube (1),
bolt with hardened washer (13). Use appropriate
cleaning solvent.
2. Discard removed parts from piston (7) and gland (2).
3. Inspect inside of tube (1) using a light source. Check
for deep grooves or scoring. If tube is damaged,
replace with new tube weldment.
4. Ensure piston rod (11) is straight. If not straight, re-
place with new piston rod.
5. Remove small scratches inside of tube (1) by using
a medium grit emery cloth. Ensure emery cloth is
applied using a circular motion.
6. Inspect bushings (12) in piston rod (11) eye and
closed end of tube (1) for damage. Replace as
required.
7. Inspect gland (2) for rust. Clean as required.
8. Inspect gland end of tube (1) for sharp edges, which
could damage gland O-ring. Remove as required.
9. Inspect piston (7) for damage or excessive wear. If
damaged or worn, replace with new piston.
10. Inspect all seals for damage or excessive wear. Re-
place as required.
Next operation:
Boom cylinder - Assemble - Boom cylinder (35.736)
47365539 08/07/2012
35.736 / 11
Boom cylinder - Assemble - Boom cylinder

Refer to illustration Boom cylinder - Exploded view (35.736).
Prior operation:
1. Install cast iron ring (8) in gland (2).

2. Install rod and buffer seal (6) in gland (2). Ensure lip
side of buffer seal faces small end of gland.
3. Install static head seal (5) in gland (2). Ensure lip of
seal faces small end of gland . Seal can be difficult
to install. Use the tool shown on CAS1660.
4. Install new wiper (4) in gland (2). Ensure lips of wiper
faces large end of gland .
7. Fasten piston rod (11) eye in vise.
8. Remove sharp edges or marks on chamfer at end of
piston rod (11).
9. Use clean oil to lubricate bore of gland (2) and piston
rod (11).
10. Slide gland (2) on piston rod (11). If required, use
soft hammer to drive gland onto piston rod.
11. Place a support below and near end of piston rod
(11). To prevent damage to piston (7), use a shop
cloth between support and piston rod.
12. Position piston (7) on end of piston rod (11).
13. Clean threads on piston rod and bolt using Loctite
cleaning solvent. Allow to dry.
14. Apply LOCTITE® 243 to piston rod threads approxi-
mately 6.35 mm (0.25 in) from open end of piston
rod. Ensure threads are minimally coated 12.7 mm
(0.50 in). Do not apply Loctite to the first 6.35 mm
(0.25 in) threads of piston rod.
15. Install and tighten bolt with hardened washer (13). A
torque multiplier can aid tightening bolt to the follow-
ing torque value:
• 580N, 580SN, and 580SN WT– 2160 - 2450
N·m (1593 - 1807 lb ft)
• 590SN – 2830 - 3210 N·m (2087 - 2368 lb ft)
16. Install new wear ring (9) in groove located in center
of piston (7).
17. Install 4 piece piston seal assembly (10) in groove
located on outside end of piston (7). Seal must be in
groove at end of the piston with large bore.
18. Install cast iron ring (8) in remaining outside groove
piston (7).
19. Fasten tube (1) in vise. Use care to prevent damage
to tube.
20. Use clean oil to lubricate inside of tube (1) and piston
(7).
21. Push piston (7) straight into tube (1).
47365539 08/07/2012
35.736 / 12
22. When the piston (7) is in smooth part of tube (1), slide
gland (2) into the tube (1).
23. Use clean oil to lubricate static head seal (5) located
on gland (2).
24. Tighten gland (2) to 135 - 542 N·m (100 - 400 lb ft).
25. Ensure tube (1) lock screw hole aligns with hole in
gland (2) after setting torque.
If holes align, do the following:
• Install and tighten lock screw (14) to torque
value of 2.3 N·m (20 lb in).
If holes do not align, do the following:
A. If required, tighten gland (2) so screw hole on
tube (1) does not align with gland wrench holes
located on face of gland.
B. Use a No. 26 drill bit to drill a hole 11 mm (0.43
in) deep, as measured from outside of tube (1).
C. Install and tighten lock screw (14) to torque of
2.3 N·m (20 lb in).
26. If equipped, install new O-rings on hose fittings. Use
clean oil to lubricate the O-rings. Install the hoses.
Next operation:
Boom cylinder - Install - Boom cylinder (35.736)
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Boom cylinder - Install - Boom cylinder

Prior operation:
1. Move the cylinder (1) into position in the boom arm

(2). Align the cylinder eyelet with the boom arm
opening.
RCPH10TLB778AAD 1
2. Insert the upper cylinder pin.
RCPH10TLB779AAD 2
3. Secure the pin in place with a retaining washer (1)

and a snap ring (2).
RCPH10TLB589AAD 3
4. Adjust the cylinder rod length until the cylinder rod

eyelet is aligned with the swing tower opening.
RCPH10TLB584AAD 4
47365539 08/07/2012
35.736 / 14
5. Insert the pin.

6. Secure the pin in place with a retaining washer (1)
and a snap ring (2).
RCPH10TLB588AAD 5
7. Connect the previously disconnected hydraulic tubes

or hoses to the boom cylinder.
8. Remove the boom cylinder lifting device.
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Boom relief valve - Pressure test
RCPH10TLB057GAL 1
1. Swing B 3. Dipper B 5. Swing A 7. Dipper A

2. Boom B 4. Bucket B 6. Boom A 8. Bucket A
1. Remove the suspect relief valve.

2. Connect the relief valve to the test block.
ducer to the test block. Set the transducer to 600
Bar.
34500 kPa (5000 psi) or greater.
4. Actuate the hand pump and record the highest pres-
sure reading. Check the pressure setting several
time to verify the reading.
5. Compare the reading with the Specifications.
See Hydraulic systems - General specification
(35.000).
6. If the pressure setting is not correct, replace the cir-
cuit relief valve. See Boom relief valve - Replace
(35.736).
47365539 08/07/2012
35.736 / 16
Boom relief valve - Replace

1. Remove the circuit relief valve from the test block.
2. Lubricate the O-ring with hydraulic oil.
3. Install the relief valve and torque to 65 N·m (48 lb ft)
± 6.8 N·m (5 lb ft).
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Index

Boom cylinder - Assemble - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Boom cylinder - Disassemble - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Boom cylinder - Exploded view - Boom cylinder (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Boom cylinder - Install - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Boom cylinder - Overhaul - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Boom cylinder - Remove - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Boom cylinder - Torque - Boom cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Boom relief valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Boom relief valve - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Dipper hydraulic system - 737
580N
580SN WT
580SN
590SN
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35.737 / 1
Contents
TECHNICAL DATA
Dipper cylinder
Torque - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Dipper cylinder
Exploded view - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Dipper cylinder
Remove - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassemble - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Overhaul - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assemble - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Dipper relief valve
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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CONSUMABLES INDEX
Consumable IU PAGE
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Hydraulic systems - Dipper hydraulic system
Dipper cylinder - Torque - Dipper cylinder

580N, 580SN, and 580SN WT

590SN
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Dipper cylinder - Exploded view - Dipper cylinder

(A) Dipper cylinder assembly (9) Wear ring
(2) Gland (11) Internal bushing
(3) Wiper rod (12) Piston rod
(5) Bearing rod (14) Locking screw
(6) Static head seal (15) Lube fitting
(8) Cast iron ring
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RCPH11TLB018HAN 1
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Dipper cylinder - Remove - Dipper cylinder

Be prepared to cap or plug hydraulic tubes, hoses, or ports.
The dipper removal procedure is the same for standard dipper and Extendahoe models.
Prior operation:
Boom cylinder - Remove - Boom cylinder (35.736)
1. Remove cylinder tube clamps.
RCPH10TLB576AAD 1
2. Remove the cylinder hydraulic tubes.
RCPH10TLB577AAD 2
RCPH10TLB579AAD 3
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3. Cap or plug hydraulic tubes and hoses.
RCPH10TLB572AAD 4
RCPH10TLB571AAD 5
5. Remove snap ring and washer from the dipper cylin-

der and arm connection.
6. Remove the dipper cylinder pin.
RCPH10TLB581AAD 6
7. Remove the snap ring and washer from the dipper

cylinder boom arm connection.
8. Remove the dipper cylinder pin.
RCPH10TLB580AAD 7
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9. Remove the cylinder from the boom arm.
RCPH10TLB569AAD 8
Next operation:
Dipper cylinder - Disassemble - Dipper cylinder (35.737)
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Dipper cylinder - Disassemble - Dipper cylinder

Prior operation:
Dipper cylinder - Remove - Dipper cylinder (35.737)
NOTE: Refer to illustration Dipper cylinder - Exploded view - Dipper cylinder (35.737).
1. Clean the outside of cylinder.
2. Secure tube (1) in a vise. Use care to prevent dam-
age to tube.
3. Remove lock screw (14) from gland (2) and tube (1).
4. Use gland wrench to remove gland (2) from tube (1).
5. Pull piston rod (12) straight out of tube (1) to prevent
damage to tube.
6. Secure piston rod (12) eye in a vise. Place a support
below piston rod near the piston (7). Use a shop cloth
between the support and the piston rod to prevent
damage to the piston rod.
7. Remove bolt with hardened washer (13). If neces-
sary use a torque multiplier.
8. Remove piston (7) from the piston rod (12).
9. Remove gland (2) from piston rod (12).
10. Remove four piece piston seal assembly (10), wear
ring (9), and cast iron ring (8) from piston (7).
11. Remove static head seal (6), rod bearing (5), rod and
buffer seal (4), and wiper rod (3), from gland (2).
Next operation:
Dipper cylinder - Overhaul - Dipper cylinder (35.737)
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Dipper cylinder - Overhaul - Dipper cylinder

Prior operation:
Dipper cylinder - Disassemble - Dipper cylinder (35.737)
NOTE: Refer to illustration Dipper cylinder - Exploded view (35.737).

1. Clean piston (7), gland (2), piston rod (12), tube (1),
and bolt with hardened washer (13). Use appropriate
cleaning solvent.
2. Discard removed parts from piston (7) and gland (2).
3. Inspect inside of tube (1) using a light source. Check
for deep grooves or scoring. If tube is damaged,
replace with new tube weldment.
4. Ensure piston rod (11) is straight. If not straight, re-
place with new piston rod.
5. Remove small scratches inside of tube (1) by using
a medium grit emery cloth. Ensure emery cloth is
applied using a circular motion.
6. Inspect bushings (12) in piston rod (11) eye and the
closed end of tube (1) for damage. Replace as re-
quired.
7. Inspect gland (2) for rust. Clean as required.
8. Inspect gland (2) end of tube (1) for sharp edges,
which could damage gland O-ring. Remove as re-
quired.
9. Inspect piston (7) for damage or wear. Replace as
required.
10. Inspect all seals for damage or excessive wear. Re-
place as required.
Next operation:
Dipper cylinder - Assemble - Dipper cylinder (35.737)
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Dipper cylinder - Assemble - Dipper cylinder
Prior operation:
Dipper cylinder - Overhaul - Dipper cylinder (35.737)
NOTE: Refer to illustration Dipper cylinder - Exploded view - Dipper cylinder (35.737).
1. Install cast iron ring (8) in gland (2).
2. Install rod and buffer seal (4) in gland (2). Lip side of
rod and buffer seal must face small end of gland.
3. Install static head seal (6) in gland (2). Seal is in-
stalled so that lips of wide seal are facing small end
of the gland. Seal can be difficult to install. Use tool
CAS1660.
4. Install new wiper (3) in gland (2). Lips of wiper must
face large end of gland.
7. Secure piston rod (12) eye in a vise.
8. Lubricate bore of gland (2) and piston rod (12) with
clean oil.
9. Push gland (2) onto piston rod (12). If necessary, use
a soft hammer to drive gland onto piston rod.
10. Put a support below and near end of piston rod (12).
To prevent piston (7) damage, use a shop cloth be-
tween support and piston rod.
11. Position piston (7) on end of piston rod (12).
12. Clean threads on end of piston rod and bolt us-
ing Loctite cleaning solvent. Allow to dry. Apply
LOCTITE® 243 to piston rod threads 6.35 mm (0.25
in) from the open end of the piston rod so that there
is 12.7 mm (0.50 in) of LOCTITE® 243 on piston rod
threads. Do not apply Loctite to the first 6.35 mm
(0.25 in) of the piston rod threads.
13. Install and tighten bolt with hardened washer (13). A
torque multiplier can be used to help tighten bolt to a
torque value of:
• 580N, 580SN, and 580SN WT – 2160 - 2450
N·m (1593 - 1807 lb ft)
• 590SN – 2830 - 3210 N·m (2087 - 2368 lb ft)
14. Install new wear ring (9) in groove in center of piston
(12).
15. Install 4 piece piston seal assembly (10) in groove
located on outside end of piston (4). Seal must be in
groove at end of piston with large bore.
16. Install cast iron ring (8) in remaining outside groove
of piston (7).
17. Fasten tube (15) in vise. Use care to prevent damage
to tube.
18. Use clean oil to lubricate inside of tube (1) and piston
(7).
19. Push piston (7) straight into tube (1).
20. When piston (7) is in smooth part of tube (1), slide
gland (2) into the tube.
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21. Use clean oil to lubricate static head seal (6) located
on gland (2) .
22. Tighten gland (2) to 135 - 542 N·m (100 - 400 lb ft).
23. Ensure tube (1) lock screw hole aligns with the hole
in gland (2) after setting torque.
If holes align, do the following:
• Install and tighten lock screw (14) to a torque
value of 2.3 N·m (20 lb in).
If holes do not align, do the following:
A. If necessary, tighten gland (2) so screw hole on
tube (1) does not align with gland wrench holes
on face of gland.
B. Use a No. 26 drill bit to drill a hole 11 mm
(0.43 in) deep as measured from outside of
tube (23).
C. Install and tighten lock screw (14) to a torque
of 2.3 N·m (20 lb in).
24. If equipped, install new O-rings on hose fittings. Use
clean oil to lubricate O-rings. Install the hoses.
Next operation:
Dipper cylinder - Install - Dipper cylinder (35.737)
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Dipper cylinder - Install - Dipper cylinder

The dipper install procedure is the same for standard dipper and Extendahoe models.
Prior operation:
Dipper cylinder - Assemble - Dipper cylinder (35.737)
1. Position the cylinder inside the boom arm.

2. Install the cylinder pin for the boom to dipper cylinder
connection.
RCPH10TLB569AAD 1
3. Secure the pin with a washer and snap ring.

4. Adjust the cylinder rod and install the cylinder pin for
the dipper arm to cylinder connection.
RCPH10TLB580AAD 2
5. Secure with a washer and snap ring.
RCPH10TLB581AAD 3
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6. Connect the cylinder hydraulic tubes.
RCPH10TLB577AAD 4
RCPH10TLB579AAD 5
7. Secure the cylinder tubes with clamps.
RCPH10TLB576AAD 6
8. Connect hydraulic hoses.
RCPH10TLB572AAD 7
Next operation:
Boom cylinder - Install - Boom cylinder (35.736)
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Dipper relief valve - Pressure test
RCPH10TLB057GAL 1


Bar.
(35.000).
cuit relief valve. See Dipper relief valve - Replace
(35.737).
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Dipper relief valve - Replace

± 6.8 N·m (5 lb ft).
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Index

Dipper cylinder - Assemble - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dipper cylinder - Disassemble - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dipper cylinder - Exploded view - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dipper cylinder - Install - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Dipper cylinder - Overhaul - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dipper cylinder - Remove - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dipper cylinder - Torque - Dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dipper relief valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Dipper relief valve - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Excavator and backhoe bucket hydraulic system - 738
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
Bucket cylinder
Torque - Arm tool attachment cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Bucket cylinder
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE
Bucket cylinder
Remove - Backhoe Dipper Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install Backhoe Dipper Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tilting relief valve
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 243 Bucket cylinder - Torque - Arm tool attachment cylinder 35.738 / 4
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Hydraulic systems - Excavator and backhoe bucket hydraulic system
Bucket cylinder - Torque - Arm tool attachment cylinder


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Bucket cylinder - Exploded view

(A) Arm attachment cylinder assembly (9) Wear ring
(2) Gland (11) Rod eye
(3) Rod bearing (12) Internal bushing
(4) Rod and buffer seal (13) Piston rod
(5) Static head seal (14) Bolt with hardened washer
(6) Wiper rod (15) Locking screw
(7) Piston (16) Lube fitting
(8) Cast iron ring (17) Plug O-ring
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RCPH11TLB017HAN 1
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Bucket cylinder - Remove - Backhoe Dipper Cylinder

1. Support boom and dipper arm so pins are accessible.
RCPH11TLB025AAL 1
2. Remove ram end tube clamps.
RCPH11TLB026AAL 2
3. Remove ram end hydraulic tube.
RCPH11TLB027AAL 3
4. Remove base end hydraulic tube.
RCPH11TLB028AAL 4
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5. Cap all open tubes and hoses.
RCPH11TLB029AAL 5
6. Use a suitable lifting device to support the cylinder.
RCPH11TLB030AAL 6
7. Remove rod end snap ring.
RCPH11TLB031AAL 7
8. Remove rod end pin.
RCPH11TLB032AAL 8
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9. Remove base end snap ring.
RCPH11TLB033AAL 9
10. Remove base end pin.
RCPH11TLB032AAL 10
11. Carefully remove the cylinder.
RCPH11TLB034AAL 11
Next operation:
Bucket cylinder - Install Backhoe Dipper Cylinder (35.738)
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Bucket cylinder - Install Backhoe Dipper Cylinder

1. Position the cylinder inside the dipper arm.
RCPH10TLB608AAD 1
2. Install the base end pin.
RCPH10TLB610AAD 2
3. Install the base end snap ring.
RCPH11TLB033AAL 3
4. Install the rod end pin.
RCPH11TLB032AAL 4
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5. Secure the pin with the snap ring and washer.
RCPH10TLB611AAD 5
6. Remove the supports from the cylinder.
RCPH11TLB030AAL 6
7. Connect the base end hydraulic tube.
RCPH11TLB028AAL 7
8. Install the ram end hydraulic tube.

9. Install the ram end tube clamps.
RCPH11TLB027AAL 8
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10. Remove the supports from the boom and dipper arm.
RCPH11TLB025AAL 9
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Tilting relief valve - Pressure test
RCPH10TLB057GAL 1


Bar.
(35.000).
cuit relief valve. See Tilting relief valve - Replace
(35.738).
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Tilting relief valve - Replace

± 6.8 N·m (5 lb ft).
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Index

Bucket cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bucket cylinder - Install Backhoe Dipper Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bucket cylinder - Remove - Backhoe Dipper Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bucket cylinder - Torque - Arm tool attachment cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tilting relief valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Tilting relief valve - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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Swing arm hydraulic system - 739
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
Swing cylinder
Torque - Swing cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Swing cylinder
Exploded view - Swing tower cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Sectional view - Swing cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
Swing cylinder
Remove - Swing cylinder (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Disassemble - Swing cylinders (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Overhaul - Swing cylinders (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Assemble - Swing cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Install - Swing cylinders (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Relief valve
Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 243 Swing cylinder - Torque - Swing cylinder 35.739 / 4
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Hydraulic systems - Swing arm hydraulic system
Swing cylinder - Torque - Swing cylinder


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Swing cylinder - Exploded view - Swing tower cylinder

(A) Swing tower cylinder (complete assembly)
(1) Gland
(2) Seal buffer
(3) Piston rod seal
(4) Seal protection
(5) Piston rod
(6) Snap ring
(7) Bushing
(8) Lubrication fitting
(9) Snap ring
(10) Bushing
(11) Backup ring
(12) O-ring
(13) Piston ring
(14) Gasket
(15) Oil seal
(16) Piston
(17) Cast iron oil seal
(18) Bolt with hardened washer
(19) Bushing
(20) Self tapping lock screw
(22) Bushing
(23) Cylinder tube
(25) O-ring
(26) Backup ring
(27) Cap
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RCPH10TLB003HAD 1
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Swing cylinder - Sectional view - Swing cylinder

(1) Gland
(2) Seal buffer
(3) Piston rod seal
(4) Seal protection
(5) Piston rod
(6) Snap ring
(7) Bushing
(9) Snap ring
(10) Bushing
(11) Backup ring
(12) O-ring
(13) Piston ring
(14) Gasket
(15) Oil seal
(16) Piston
(17) Cast iron oil seal
(18) Bolt with hardened washer
(19) Bushing
(22) Bushing
(23) Cylinder tube
(25) O-ring
(26) Backup ring
(27) Cap
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RCPH10TLB143GAL 1
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Swing cylinder - Remove - Swing cylinder (all models)

WARNING
Pressurized hydraulic fluid can penetrate the skin and cause severe injuries.
Hydraulic fluid is under extreme pressure. Rest the bucket or attachment on the ground. Shut the
engine off, turn the key on, and move the hydraulic control lever through all movements several times
to relieve residual pressure in the system.
W0161A
When disconnecting hydraulic components be prepared to cap and plug hoses and ports. Direct the flow of oil into a
suitable container.
1. Extend and support the backhoe boom. Turn the

engine off, remove the ignition key and release the
pressure in the hydraulic system.
2. Identify and tag the swing cylinder hoses.
RCPH10TLB061AAD 1
3. Remove the top support mount hardware.
RCPH10TLB069AAD 2
4. Remove the cylinder top mount support. Record the

location and number of shims.
RCPH10TLB055AAD 3
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5. Remove the swing cylinder hose clamps.
RCPH10TLB059AAD 4
6. Remove the hydraulic hoses. Cap all open ports.
RCPH10TLB063AAD 5
7. Remove quick detach hose bracket.
RCPH10TLB057AAD 6
8. Remove the rod end snap ring and washer.

9. Remove pin.
RCPH10TLB094AAD 7
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10. Compress piston rod into the cylinder.
RCPH10TLB054AAD 8
11. Carefully remove the cylinder.
RCPH10TLB051AAD 9
Next operation:
Swing cylinder - Disassemble - Swing cylinders (all models) (35.739)
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Swing cylinder - Disassemble - Swing cylinders (all models)

Prior operation:
Swing cylinder - Remove - Swing cylinder (all models) (35.739)
NOTE: Refer to illustrations Swing cylinder - Exploded view - Swing tower cylinder (35.739) and Swing cylinder
- Sectional view - Swing cylinder (35.739).
1. Clean the outside of the cylinder.
2. Fasten the tube (23) in a vise or other holding equip-
ment. Be careful to prevent damage to the tube (23).
3. Remove the lock screw (20) from the gland (1) and
tube (23).
4. Use the gland wrench CAS1456 to remove the gland
(1) from the tube (23).
5. Pull the piston rod (5) straight out of the tube (23) to
prevent damage to the tube (23).
6. Fasten the piston rod (5) eye in a vise and put a
support below the piston rod (5) near the piston (16).
Use a shop cloth between the support and the piston
rod (5) to prevent damage to the piston rod (5).
7. Remove the bolt with hardened washer (18). If nec-
essary use tool CAS1039.
8. Remove the piston (16) from the piston rod (5).
9. Remove the gland (1) from the piston rod (5).
10. Remove the wear ring (15), seal (17), backup ring
(14), and piston ring (13) from the piston (16).
11. Remove the O-ring (12), backup ring (11), wiper (3),
wide seal (4), buffer seal (2), and bushing (10) from
the gland (1).
12. Remove the end cap lock screw (24).
13. Remove the end cap (13) from the tube (23).
14. Remove the backup ring (26) and O-ring (25) from
the end cap (27).
Next operation:
Swing cylinder - Overhaul - Swing cylinders (all models) (35.739)
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Swing cylinder - Overhaul - Swing cylinders (all models)

Prior operation:
Swing cylinder - Disassemble - Swing cylinders (all models) (35.739)
1. Clean the piston (16), gland (1), piston rod (5), tube
(23), bolt with hardened washer (18) in cleaning sol-
vent. Make sure the orifice in the piston (16) is open.
2. Discard the parts that were removed from the piston
(16), gland (1) and the end cap (27).
3. Illuminate the inside of the tube (23). Inspect the
inside of the tube (23) for deep grooves and other
damage. If there is damage to the tube (23), a new
tube (23) must be used.
4. Check to be sure that the piston rod (5) is straight. If
the piston rod (5) is not straight, install a new piston
rod (5).
5. Remove small scratches on the piston rod (5) or in-
side the tube (23) with emery cloth of medium grit.
Use the emery cloth with a rotary motion.
6. Inspect the bushing (7) and snap rings (6): (9) in the
piston rod (5) eye and bushings (19): (22) on the
trunnions on the tube (23), replace as required.
7. Inspect the gland (1). Clean and remove rust as re-
quired.
8. Inspect the gland end of the tube (23) for sharp edges
that will cut the gland O-ring (12), remove as re-
quired.
Next operation:
Swing cylinder - Assemble - Swing cylinders (35.739)
47365539 08/07/2012
35.739 / 14
Swing cylinder - Assemble - Swing cylinders
Prior operation:
Swing cylinder - Overhaul - Swing cylinders (all models) (35.739)
NOTE: If a new gland (1) is being installed, put the part number of the cylinder on the new gland.
1. Install the bushing (10) in the gland (1).
2. Install the buffer seal (2) in the gland (1). The side
of the buffer seal (2) with the lip must be toward the
small end of the gland (1).
3. Install the wide seal (4) in the gland. The wide seal
(4) is to be installed so that the lips of the wide seal
(4) are toward the small end of the gland (1). The
wide seal (4) can be difficult to install. If necessary
use tool CAS1039.
4. Install a new wiper (3) in the gland (1). The lips of the
wiper (3) must be toward the large end of the gland
(1).
5. Install a new backup ring (11) in the groove on the
outside of the gland (1). If both sides of the backup
ring (11) are not flat, the side that is not flat must be
toward the small end of the gland (1).
6. Install the O-ring (12) next to the backup ring (11) in
the groove on the outside of the gland (1). The O-ring
(12) must be toward the small end of the gland (1).
7. Fasten the piston rod (5) eye in the vise.
8. Lubricate the bore of the gland (1) with clean oil.
9. Push the gland (1) onto the piston rod (5). If neces-
sary, use a soft hammer to drive the gland (1) onto
the piston rod (5).
10. Put a support below and near the end of the piston
rod (5). Use a shop cloth between the support and
the piston rod (5) to prevent damage to the piston
(16).
11. Put the piston (16) on the end of the piston rod (5).
12. Clean the threads on the end of the piston rod and
the threads of the bolt using Loctite cleaning sol-
vent. Allow to dry. Apply LOCTITE® 243 to the piston
rod threads 6.35 mm (0.25 in) from the open end of
the piston rod so that there is 3.7 mm (0.15 in) of
LOCTITE® 243 on the piston rod threads. Do not ap-
ply Loctite to the first 6.35 mm (0.25 in) of the piston
rod threads.
13. Install and tighten the bolt (18) to a torque value be-
tween 810 - 925 N·m (597 - 682 lb ft). A torque mul-
tiplier tool CAS1039 can be used to tighten the bolt
within the torque specifications.
14. Install a new piston ring (13) in the groove at the bolt
end of the piston (16).
15. Install a new wear ring (15) in the center grove on the
outside of the piston (16).
16. Install a new backup ring (14) in the groove on the
outside of the piston (16).
47365539 08/07/2012
35.739 / 15
17. Install a new seal (17) on top of the backup ring (14)
on the outside of the piston (16).
18. Fasten the tube (23) in a vise or other holding equip-
19. Install a new backup ring (26) and O-ring (25) in the
groove on the outside of the end cap (23).
20. Lubricate the O-ring (25) on the end cap (27) with
clean oil.
21. Install the end cap (27) in the tube (23).
22. Install and tighten the lock screw (24) to a torque of
2.3 N·m (20 lb in).
23. Lubricate the inside of the tube (23) and the piston
(16) with clean oil.
24. Use a piston ring compression tool to hold the new
wear ring (15) in place.
25. Push the tube (23) straight onto the piston (16).
26. Start the tube (23) onto the piston rod assembly.
Push the tube onto the piston rod assembly until the
compression tool is pushed off the piston rod assem-
bly. Be careful not to damage the wear ring (15) and
seal (17).
27. Lubricate the O-ring (12) on the gland (1) with clean
oil.
28. Tighten the gland (1) to 135 - 542 N·m (100 - 400 lb
ft).
29. Confirm the tube (23) lock screw hole aligns with the
hole in the gland (1) after setting the torque.
Holes align:
• Install and tighten the lock screw (20) to a
torque value of 2.3 N·m (20 lb in).
Holes not aligned:
A. If necessary, tighten the gland (1) so the screw
hole on the tube (23) does not align with the
gland wrench holes on the face of the gland.
B. Use a No. 26 drill bit and drill a hole 11 mm
(0.43 in) deep measured from the outside of
the tube (23).
C. Install and tighten the lock screw (20) to a
torque of 2.3 N·m (20 lb in).
Next operation:
Swing cylinder - Install - Swing cylinders (all models) (35.739)
47365539 08/07/2012
35.739 / 16
Swing cylinder - Install - Swing cylinders (all models)

Prior operation:
Swing cylinder - Assemble - Swing cylinders (35.739)
1. Position the swing cylinder on the machine.

NOTE: Replicate the original location and number of shims
on the cylinder.
RCPH10TLB051AAD 1
2. Extend and align the cylinder rod eyelet with the

swing tower opening.
RCPH10TLB054AAD 2
3. Install the swing cylinder pin. Secure the pin with a

snap ring (1) and washer (2).
RCPH10TLB090AAD 3
4. Secure the quick detach hose bracket.
RCPH10TLB057AAD 4
47365539 08/07/2012
35.739 / 17
5. Attach cylinder hoses and remove the identification

tags.
RCPH10TLB063AAD 5
6. Secure the hoses to the cylinder with clamps.
RCPH10TLB059AAD 6
7. Position the cylinder top support retaining bracket (1)

over the swing cylinder (2).
RCPH10TLB055AAD 7
8. Tighten the bolt hardware to a torque of 410 - 455

N·m (302 - 336 lb ft).
RCPH10TLB069AAD 8
47365539 08/07/2012
35.739 / 18
Relief valve - Pressure test
RCPH10TLB057GAL 1


Bar.
(35.000).
6. If the pressure setting is not correct, replace the
circuit relief valve. See Relief valve - Replace
(35.739).
47365539 08/07/2012
35.739 / 19
Relief valve - Replace

± 6.8 N·m (5 lb ft).
47365539 08/07/2012
35.739 / 20
Index

Relief valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Relief valve - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Swing cylinder - Assemble - Swing cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Swing cylinder - Disassemble - Swing cylinders (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Swing cylinder - Exploded view - Swing tower cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Swing cylinder - Install - Swing cylinders (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Swing cylinder - Overhaul - Swing cylinders (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Swing cylinder - Remove - Swing cylinder (all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Swing cylinder - Sectional view - Swing cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Swing cylinder - Torque - Swing cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47365539 08/07/2012
35.739 / 21
47365539 08/07/2012
35.739 / 22
Telescopic arm hydraulic system - 740
580N
580SN WT
580SN
590SN
47365539 08/07/2012
35.740 / 1
Contents
TECHNICAL DATA
Telescopic arm cylinder

Torque - Extendable dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Telescopic arm cylinder

Exploded view - Extendable dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
47365539 08/07/2012
35.740 / 2
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 243 Telescopic arm cylinder - Torque - Extendable dipper cylinder 35.740 / 4
47365539 08/07/2012
35.740 / 3
Hydraulic systems - Telescopic arm hydraulic system
Telescopic arm cylinder - Torque - Extendable dipper cylinder


47365539 08/07/2012
35.740 / 4
47365539 08/07/2012
35.740 / 5
Telescopic arm cylinder - Exploded view - Extendable dipper

cylinder
(A) Extendable dipper cylinder assembly (8) Cylinder
(1) Cylinder tube (9) Loader
(2) Gland (10) Piston
(3) Backup ring (11) Wear ring
(4) Rod and buffer seal (12) Piston rod
(5) Wiper rod (13) Bolt with hardened washer
(6) Bearing rod (14) Locking screw
(7) O-ring (15) Plug with O-ring
47365539 08/07/2012
35.740 / 6
RCPH11TLB020HAN 1
47365539 08/07/2012
35.740 / 7
Index

Telescopic arm cylinder - Exploded view - Extendable dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Telescopic arm cylinder - Torque - Extendable dipper cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
47365539 08/07/2012
35.740 / 8
47365539 08/07/2012
35.740 / 9
PRINTED IN U.S.A.
47365539 08/07/2012
EN
SERVICE MANUAL
Frames and ballasting
580N
580SN WT
580SN
590SN
47365539 08/07/2012
39
Contents
Frames and ballasting - 39
Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.100
580N , 580SN WT , 580SN , 590SN
Stabilizers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.129
580N , 580SN WT , 580SN , 590SN
47365539 08/07/2012
39
Frame - 100
580N
580SN WT
580SN
590SN
47365539 08/07/2012
39.100 / 1
Contents
Frame - 100
SERVICE
Front frame
Remove - Loader Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Install - Loader Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
47365539 08/07/2012
39.100 / 2
Frames and ballasting - Frame
Front frame - Remove - Loader Frame

1. Position loader above hood to access cylinder pins.
RCPH11TLB098AAM 1
2. Install lifting device.
RCPH11TLB099AAM 2
3. Remove the left-hand and right-hand rod end snap

rings.
RCPH11TLB100AAM 3
4. Remove the left-hand and right-hand rod end pins.

Leave tool in place to hold cylinder.
RCPH11TLB101AAM 4
47365539 08/07/2012
39.100 / 3
RCPH11TLB102AAM 5
6. Lower loader frame to the floor.
RCPH11TLB103AAM 6
7. Support the left-hand cylinder. Remove the tool and

safety lock.
RCPH11TLB104AAM 7
8. Lower the left-hand and right-hand cylinders onto the

front axle.
RCPH11TLB105AAM 8
47365539 08/07/2012
39.100 / 4
9. Turn the ignition to the ON position. Relieve pressure

from the hydraulic lines by moving the control stick in
all positions.
RCPH11TLB106AAM 9
10. Identify, tag and disconnect bucket hoses from the

right-hand side.
RCPH11TLB107AAM 10
11. Identify, tag and disconnect bucket hoses from the

left-hand side.
RCPH11TLB108AAM 11
12. Cap open hydraulic lines.
RCPH11TLB109AAM 12
47365539 08/07/2012
39.100 / 5
13. Remove the Return To Dig switch.
RCPH11TLB110AAM 13
14. Disconnect anti-rollback rod from the bucket link.
RCPH11TLB111AAM 14
15. Disconnect the anti-rollback rod self leveling cam.
RCPH11TLB112AAM 15
16. Remove the right-hand side snap ring (1).

17. Remove the right-hand side washers. (2)
RCPH11TLB113AAM 16
47365539 08/07/2012
39.100 / 6
18. Support loader with lifting device.
RCPH11TLB114AAM 17
19. Drive the pivot pin from the right-hand side.
RCPH11TLB115AAM 18
20. Remove the pivot pin.
RCPH11TLB116AAM 19
21. Remove the loader arm.
RCPH11TLB117AAM 20
47365539 08/07/2012
39.100 / 7
22. Remove the self-leveling cam and washer.
RCPH11TLB118AAM 21
47365539 08/07/2012
39.100 / 8
Front frame - Install - Loader Frame

1. Install the self-leveling cam and washer.
RCPH11TLB118AAM 1
2. Carefully move the loader arm into position.
RCPH11TLB117AAM 2
3. Drive the pivot pin into place.
RCPH11TLB116AAM 3
4. Remove the loader lifting device.
RCPH11TLB114AAM 4
47365539 08/07/2012
39.100 / 9
5. Install the right-hand washer (2). Install the right-

hand side snap ring (1).
RCPH11TLB113AAM 5
6. Connect the anti-rollback rod self leveling cam.
RCPH11TLB112AAM 6
7. Connect anti-rollback rod from the bucket link.
RCPH11TLB111AAM 7
8. Install the Return To Dig switch.
RCPH11TLB110AAM 8
47365539 08/07/2012
39.100 / 10
9. Reconnect bucket hoses on the left-hand side.
RCPH11TLB108AAM 9
10. Reconnect bucket hoses on the right-hand side.
RCPH11TLB107AAM 10
11. Raise the left-hand and right-hand cylinders into po-

sition.
RCPH11TLB105AAM 11
12. Support the left-hand cylinder. Install safety lock.
RCPH11TLB104AAM 12
47365539 08/07/2012
39.100 / 11
13. Lower loader frame to the floor.
RCPH11TLB103AAM 13
14. Install a suitable lifting device.
RCPH11TLB102AAM 14
15. Install the left-hand and right-hand rod end pins. Re-
move the tool that is holding the cylinders in place.
RCPH11TLB101AAM 15
16. Install the left-hand and right-hand rod end snap

rings.
RCPH11TLB100AAM 16
47365539 08/07/2012
39.100 / 12
RCPH11TLB099AAM 17
47365539 08/07/2012
39.100 / 13
Index
Frame - 100
Front frame - Install - Loader Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front frame - Remove - Loader Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47365539 08/07/2012
39.100 / 14
Stabilizers - 129
580N
580SN WT
580SN
590SN
47365539 08/07/2012
39.129 / 1
Contents
Stabilizers - 129
FUNCTIONAL DATA
Stabilizer
Exploded view - Stabilizer (580N, 580SN, 580SN-WT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N
47365539 08/07/2012
39.129 / 2
Frames and ballasting - Stabilizers
Stabilizer - Exploded view - Stabilizer (580N, 580SN, 580SN-WT)

580N
RCPH10TLB107GAL 1
47365539 08/07/2012
39.129 / 3
Index
Stabilizers - 129
Stabilizer - Exploded view - Stabilizer (580N, 580SN, 580SN-WT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N
47365539 08/07/2012
39.129 / 4
47365539 08/07/2012
39.129 / 5
PRINTED IN U.S.A.
47365539 08/07/2012
EN
SERVICE MANUAL
Steering
580N
580SN WT
580SN
590SN
47365539 08/07/2012
41
Contents
Steering - 41
Steering control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.101

580N , 580SN WT , 580SN , 590SN
Hydraulic control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.200

580N , 580SN WT , 580SN , 590SN
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.216
580N , 580SN WT , 580SN , 590SN
47365539 08/07/2012
41
Steering - 41
Steering control - 101
580N
580SN WT
580SN
590SN
47365539 08/07/2012
41.101 / 1
Contents
Steering - 41
FUNCTIONAL DATA
Steering column
Exploded view - Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view - Cab models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view - Canopy models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SERVICE
Steering column
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
47365539 08/07/2012
41.101 / 2
47365539 08/07/2012
41.101 / 3
Steering - Steering control
Steering column - Exploded view - Front console

1. Cover
2. O-Ring
3. Nut
4. Steering wheel
5. Bolt
6. Upper steering column cover
7. Turn signal indicator connector
8. Lower steering wheel column cover
9. Turn signal/driving light switch
10. Transmission shift lever connector
11. Power shift controller wire harness
12. Screw
13. Transmission shift lever
14. Rocker switches
15. Front console cover
47365539 08/07/2012
41.101 / 4
RCPH10TLB128GAL 1
47365539 08/07/2012
41.101 / 5
Steering column - Exploded view - Cab models
RCPH10TLB075GAL 1
Cab Models
1. Nut 5. Column
2. Nut 6. U-bolt mounting holes for tilt columns
3. Washer 7. U-bolt mounting hole for non-tilt columns
4. U-bolt
47365539 08/07/2012
41.101 / 6
Steering column - Exploded view - Canopy models
RCPH10TLB074GAL 1
Canopy Models
1. Bolt 4. Nut 7. Spacer

2. Washer 5. Washer 8. Steering column
3. Steering control valve 6. U-bolt 9. U-bolt mounting holes for non-tilt columns
47365539 08/07/2012
41.101 / 7
Steering column - Remove

parking brake.
2. Lower the bucket to the floor.
NOTE: Refer to Steering column - Exploded view
(41.101) for the following steps.
3. Remove the cover (1) from the steering wheel (4).
The cover is held by the fit of an O-ring (2).
4. Loosen and remove the nut (3) that holds the steering
wheel (4) in place. Remove the steering wheel (4).
5. Remove the screws (5) that fasten the upper and
lower steering column cover (6) and (8) in place.
6. Remove the upper steering column cover (6). Dis-
connect the wiring connector from the turn signal in-
dicator (7).
7. Remove the lower steering column cover (8). Dis-
connect the wiring connector from the turn signal/
driving light switch (9).
8. Disconnect the connector (10) from the transmission
shift lever (13).
9. Loosen and remove the screws (12) that fasten the
transmission shift lever (13) to the steering column.
Remove the transmission shift lever (13).
10. Disconnect the connectors from the rocker switches
(14) in the front console (15).
11. Remove the bolts that fasten the instrument console
cover (15) to the cab.
12. If equipped, remove the filler cap from the windshield
washer reservoir. Remove the front console (15).
13. If your machine is equipped with a cab go to step 14.
If it is equipped with a canopy go to step 16
(41.101) and Steering column - Exploded view (41.101)
for steps 14 and 15.
14. Remove the nuts (1) from the steering column (5).
15. Remove the nuts (2), washers (3), and U-bolt (4)
from the steering column (5). Go to step 18.
(41.101) for steps 16
16. Have another person hold the steering control valve
(3) in place and remove the bolts (1) and washers (2)
that fasten the steering column (8) to the canopy and
the steering control valve (3).
17. Remove the nuts (4), washers (5), U-bolt (6), and
spacer (7) from the steering column (8).
18. Remove the steering column from the machine.
Next operation:
Steering column - Install (41.101)
47365539 08/07/2012
41.101 / 8
Steering column - Install

Prior operation:
Steering column - Remove (41.101)

If it is equipped with a canopy go to step 4.
(41.101) for steps 2 and 3.
2. Grease the splines of the steering column and control
valve with high temperature grease. Put the steering
column (5) in place and install the nuts (1). Tighten
the nuts (1) to a torque of 46 - 50 N·m (34 - 37 lb ft).
3. Install the U-bolt (4), washers (3), and nuts (2). Go
to step 7.
(41.101) for steps 4 through 6.
4. Grease the splines of the steering column and control
valve with high temperature grease. Put the steering
column in place on the machine.
(3) in place. Install the washers (2) and bolts (1) that
fasten the steering column (8) to the canopy and the
steering control valve (3). Tighten the bolts (1) to a
torque of 46 - 50 N·m (34 - 37 lb ft).
6. Install the spacer (7), U-bolt (6), washers (5), and
nuts (4).
(41.101) for the following steps.
7. Put the front console cover (15) in position. If
equipped, install the cap on the windshield washer
reservoir.
8. Install the bolts that fasten the front console cover
(15) to the cab.
9. Connect the connectors to the rocker switches (14)
in the front console (15).
10. Put the transmission shift lever (13) in place. In-
stall the screws (12) that fasten the transmission shift
lever (13) to the steering column.
11. Connect the connector (10) to the transmission shift
lever.
12. Connect the wiring connector (9) to the turn signal/
driving light switch. Put the lower steering column
cover (8) in place.
13. Connect the wiring connector to the turn signal indi-
cator (7). Install the upper steering column cover (6).
14. Install the screws (5) that fasten the upper and lower
steering column cover (6) and (8) in place.
15. Put the steering wheel (4) in place. Install the nut (3)
that holds the steering wheel in place. Tighten the
nut to a torque of 41 - 54 N·m (30 - 40 lb ft)
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16. Install the cover (1) on the steering wheel (4). The
cover is held by the fit of an O-ring (2).
17. With the engine off, turn the steering wheel about 5
° in either direction. Effort will be light when work-
ing against the springs, but stiff when approaching
manual steer. Release the wheel when approaching
manual steer, and confirm the wheel returns back to
neutral freely. If not free, check the bind.
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Index
Steering - 41

Steering column - Exploded view - Cab models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Steering column - Exploded view - Canopy models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steering column - Exploded view - Front console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Steering column - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Steering column - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Steering - 41
Hydraulic control components - 200
580N
580SN WT
580SN
590SN
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Contents
Steering - 41
TECHNICAL DATA
Hydraulic control components

General specification - Steering relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General specification - Rotor and stator clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Special tools - Pressure fitting kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Special tools - Rotor and stator clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUNCTIONAL DATA
Hydraulic control components

Drawing - Steering control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drawing - Optional comfort steering control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power steering control valve
Exploded view - 580N, 580SN, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Exploded view - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Exploded view - Comfort steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Exploded view - Steering control valve - Standard Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Sectional view Standard Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Sectional view Optional Comfort Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SERVICE
Power steering control valve

Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Steering circuit relief valve
Pressure test - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Pressure test - 580SN, 580SN WT and 590SN machines only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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Steering - Hydraulic control components
Hydraulic control components - General specification

Special torques
Nut for the steering wheel 41 - 54 N·m (30.2 - 39.8 lb ft)
Steering cylinder two wheel drive axle 335 N·m (247.1 lb ft)
Steering cylinder four wheel drive axle 120 N·m (88.5 lb ft)
Front drive shaft 33 - 39 N·m (24.3 - 28.8 lb ft)
Front drive shaft guard 50 - 90 N·m (36.9 - 66.4 lb ft)
Nut that fastens the tie rod end to the pivot arm
Four wheel drive axle (580N, 580SN, 165 N·m (121.7 lb ft)
580SN-WT)
Four wheel drive axle (590SN) 220 N·m (162.3 lb ft)
Two wheel drive axle all models 165 N·m (121.7 lb ft)
Wheel nuts 4 WD axles 122 N·m (90.0 lb ft)+ 3 - 10 N·m (2.2 - 7.4 lb ft) Then turn nut
an additional 90 ° +/- 5 °
Wheel bolts 2 WD axles 251 N·m (185.1 lb ft)
Hydraulic control components - General specification - Steering

relief valve
SPECIFICATIONS
Location of steering relief valve In steering control valve
Pressure setting 172 +0/-10 bar (2500 +0/-150 psi)
Hydraulic control components - General specification - Rotor and

stator clearance
Rotor and stator clearance 0.13 mm (0.005 in)
Special torques
Allen Head Plug 11 N·m (97.4 lb in)
Ferry Head Screws 25 - 31 N·m (221.3 - 274.4 lb in)
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Hydraulic control components - Special tools

The tool shown is needed to remove the steering wheel.
Make the tool in your shop.
Make from 6 mm (0.24 in) Cold Rolled Steel
RCPH10TLB077GAL 1
1. 50.4 mm (2 in) 5. 19 mm (0.750 in)

2. 25.4 mm (1 in) 6. Two holes 5.5 mm
(0.217 in)
3. 15.9 mm (0.625 in) 7. Use No.4 drill for 1/4-24
4. 9.5 mm (0.375 in) 8. Threads metric thread
optional two 10-32 x 1 inch
screws required
CAS10486 Puller This tool is used to remove the ball joint
for the steering cylinder from the axle.
RCPH10TLB300ABL 2
380100091 for all two wheel drive and the 580N, 580SN
four wheel drive front axle. 38010092 for the 580SN+ and
590SN and 590SN+ four wheel drive front axle. This tool
is used to remove and install the tie rod.
RCPH10TLB235ABL 3
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Hydraulic control components - Special tools - Pressure fitting kit

Special Tool
RCPH10TLB234ABL 1
Hydraulic control components - Special tools - Rotor and stator

clearance
CAS-1239 Centering spring tool
RCPH10TLB233ABL 1
380002000 and 380002001
RCPH10TLB284ABL 2
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Hydraulic control components - Drawing - Steering control valve

Illustrations
RCPH10TLB001HAM 1
1. Inlet 4. Check valve 7. Gerotor

2. Outlet 5. Spool and sleeve assembly 8. Steering relief valve
3. Pilot 6. Drive link 9. Anti-cavitation relief valve
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Hydraulic control components - Drawing - Optional comfort

steering control valve
RCPH10TLB070GAL 1
1. Anti-cavitation check valve 4. Spool 7. Spool and sleeve assembly 10. Load sense
2. Gerotor 5. Solenoid 8. Check valve 11. Return
3. Gerotor 6. Drive link 9. Inlet 12. Steering relief valve
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Power steering control valve - Exploded view - 580N, 580SN, 590SN

only
Steering control valve hydraulic installation 580N, 580SN AND 590SN
RCPH10TLB071GAL 1
Steering Control Valve Hydraulic Installation 580N, 580SN and 590SN
1. Hydraulic filter 4. Return hose 7. Left hose for steering cylinder

2. Hydraulic pump 5. Pressure hose 8. Load sense hose
3. Steering pump 6. Right hose for steering cylinder
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Power steering control valve - Exploded view - 580SN-WT only

Steering control valve hydraulic installation 580 SN-WT only
RCPH10TLB072GAL 1
1. Hydraulic filter 4. Return hose 7. Left hose for steering cylinder

2. Loader valve 5. Pressure hose 8. Load sense hose
3. Steering pump 6. Right hose for steering cylinder
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Power steering control valve - Exploded view - Comfort steering

valve
RCPH10TLB073GAL 1
1. Pressure hose to solenoid 4. Return hose to reservoir 7. Hydraulic filter

2. Steering pump 5. Comfort steer solenoid
3. Pressure hose from solenoid 6. Solenoid to tank fitting
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Power steering control valve - Exploded view - Steering control

valve - Standard Steering
RCPH10TLB076GAL 1
1. Cap Screws 7. O-ring 13. Sleeve 19. Needle thrust bearing

2. End plate 8. Gerotor 14. Pin 20. Bearing race
3. Spring 9. O-ring 15. Spring retainer 21. O-ring
4. Pin 10. Drive shaft 16. Centering spring 22. Seal half
5. Spring 11. Spacer plate 17. O-ring 23. Housing
6. Ball 12. Spool 18. Bearing race 24. Dust seal
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Power steering control valve - Sectional view Standard Steering

Control Valve
RCPH10TLB001HAM 1
1. Inlet 4. Check Valve 7. Gerotor

2. Outlet 5. Spool and Sleeve Assembly 8. Steering Relief Valve
3. Load Sense 6. Drive Link 9. Anti-cavitation check valve
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Power steering control valve - Sectional view Optional Comfort

Steering Control Valve
RCPH10TLB070GAL 1
1. Anti-Cavitation Check Valve 4. Spool 7. Spool and Sleeve Assembly 10 Load Sense
2. Gerotor 5. Solenoid 8. Check Valve 11. Return
3. Gerotor 6. Drive Link 9. Inlet 12. Steering Relief Valve
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Power steering control valve - Remove
NOTE: Put identification tags on all disconnected hoses.

Close disconnected hoses and fittings with caps and plugs.
parking brake.
2. Raise the loader and lock the support strut to hold
the loader.
3. Open the hood.
4. Tag and disconnect the wires for the air restriction
switch. Cut the tie strap from the wires.
RCPH10TLB025AAL 1

nect the air cleaner hose from the turbo. Put a shop
cloth in the turbo opening or the intake opening.
RCPH10TLB024AAL 2
6. Remove the bolts and flat washers that fasten the

fixed hood to the uprights. Use acceptable lifting
equipment and remove the fixed hood and air cleaner
as an assembly.
RCPH10TLB023AAL 3
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the hole in the curtain. Remove the bolts and the
engine curtain from the engine compartment.
RCPH10TLB240ABL 4
8. Tag and disconnect the hoses from the fittings in the

steering control valve.
NOTE: Refer to illustration this page for the following steps.
RCPH10TLB289ABL 5
9. If your machine has a cab go to step 12. If the ma-

chine has a canopy go to step 10.
in position. Remove the bolts (1) and washers (2)
that fasten the steering control valve (3) to the steer-
ing column.
11. Remove the steering control valve from the canopy.
12. Remove the bolts (4), washers (5), and mount (6)
that fasten the steering control valve (7) to the cab.
13. Remove the steering control valve (7), mount (8),
and spacer (9) from the cab.
RCPH10TLB066GAL 6
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1. Bolt 6. Mount
2. Washer 7. Control Valve
3. Control valve 8. Mount
4. Bolt 9. Spacer
5. Washer
Next operation:
Power steering control valve - Install (41.200)
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Power steering control valve - Install

Prior operation:
Power steering control valve - Remove (41.200)

in position.
If it is equipped with a canopy go to step 5.
NOTE: Refer to illustration.
3. Put the spacer (9), mount (8), and steering control
valve (7) into position.
4. Install the mounts (6), washers (5), and bolts (4). Go
to step 7.
5. Put the steering control valve (3) into position.
6. Install the washers (2) and bolts (1) that fasten the
steering control valve (3) to the steering column.
7. Connect hoses to the fittings on the steering control
valve, remove the tags.
RCPH10TLB289ABL 1
8. Remove the shop cloth from the turbo opening, start

and run the engine at low idle.
9. Turn the steering wheel all the way to the right and
left several times to remove any air from the steering
system.
10. Stop the engine and check for oil leaks, put a shop
cloth in the turbo opening.
as required.
the hole in the engine curtain. Put the engine curtain
in position on the mounting bracket and install the
bolts that fasten the engine curtain to the mounting
bracket.
RCPH10TLB240ABL 2
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13. Put the fixed hood and air cleaner assembly in posi-
tion on the uprights. Install the bolts and flat washers
that fasten the fixed hood to the uprights.
RCPH10TLB023AAL 3
14. Remove the shop cloth from the turbo opening. Con-
nect the air cleaner hose to the turbo. Tighten the
clamp on the air cleaner hose.
RCPH10TLB024AAL 4
15. Connect the electrical connector for the air restriction

switch. Install a new tie strap.
RCPH10TLB025AAL 5
16. Close the hood.
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Power steering control valve - Disassemble

1. Mark the pump for proper alignment during assem-
bly.
RCPH10TLB241ABL 1
2. Put the steering control valve in the vise so that the

end plate is up.
RCPH10TLB242ABL 2
3. Remove the cap screws and end cap.
RCPH10TLB243ABL 3
4. Remove the O-ring from the stator of the metering

gear set.
RCPH10TLB244ABL 4
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5. Lift the spacer plate from the body.
RCPH10TLB245ABL 5
6. Remove the metering gear from the pump.
RCPH10TLB246ABL 6
7. Remove the O-ring from the spacer plate, remove the

spacer plate. Remove and discard the O-ring from
the body.
RCPH10TLB247ABL 7
8. Find the anti-cavitation valves (1) in the body. Put

identification marks on the body for use during as-
sembly.
RCPH10TLB248ABL 8
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9. Remove the 4 springs, the pins, and the balls from

the ports in the body.
RCPH10TLB249ABL 9
10. Find the manual steering check valve. Remove the

manual steering check valve ball and roll pin.
NOTE: The manual steering check valve is located in the
bolt hole with the thread insert.
RCPH10TLB250ABL 10
11. Pull the sleeve and spool out of the body.

NOTE: The diagram shows the steering control in a hori-
zontal position, disassemble steering control unit in a verti-
cal position, the pin that links the sleeve, spool, and driver
could possibly slip and lock the parts in the housing.
RCPH10TLB251ABL 11
12. Use a punch to push the pin out of the sleeve and
spool.
RCPH10TLB252ABL 12
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13. Remove the drive shaft from the sleeve and spool.
RCPH10TLB253ABL 13
14. Remove the thrust washer, the thrust bearing, and

lower thrust washer.
RCPH10TLB254ABL 14
15. Remove the spring retainer.

NOTE: Hold the spring into the sleeve and spool while re-
moving the ring, they can come out unexpectedly.
RCPH10TLB255ABL 15
16. Remove the springs and centering spacers from the

sleeve and spool.
RCPH10TLB256ABL 16
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17. Pull the spool straight out of the sleeve.
RCPH10TLB257ABL 17
18. There are four centering springs and three spacers.
RCPH10TLB258ABL 18
19. Remove the seal from the gland.
RCPH10TLB259ABL 19
20. Remove the spool seal.
RCPH10TLB260ABL 20
Next operation:
Power steering control valve - Inspect (41.200)
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Power steering control valve - Inspect

Prior operation:
Power steering control valve - Disassemble (41.200)
Use cleaning solvent to clean all parts. Put the parts on

paper towels until the parts are dry. Do not use cloths to
wipe the parts dry.
Check all machined surfaces for wear or damage. If there
are rough places on the ends of the stator and rotor or on
the machined surfaces on the body, end plate, or spacer
plate, use 600 grit emery cloth to make the surfaces
smooth. Put the emery cloth on a flat surface. If the emery
cloth is new, move a piece of steel across the emery cloth
six times to remove the sharp pieces of grit. Move the
rotor, stator, body, end plate, or spacer across the emery
cloth six times. Then check to see if the rough places have
been removed. Use this method until all rough places are
gone. Make sure that you keep the part flat on the emery
cloth as you move the part across the emery cloth. Use
cleaning solvent to remove any grit from the parts.
RCPH10TLB064GAL 1
1. If the spool (1), sleeve (2), or bore in the body (3)is

damaged or worn, replace the steering control valve.
The spool (1), sleeve (2), and body (3) are not avail-
able separately.
2. Inspect the thrust washers (1) and the thrust bearing
(2) for damage or wear. Replace as required.
RCPH10TLB065GAL 2
3. Inspect the springs, the pins, and the balls of the

anticavitation valve for damage or wear. Use new
parts as required.
4. Inspect the roll pin and ball of the manual steering
valve for damage or wear. Use new parts as re-
quired.
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tween the rotor and the stator. If the clearance is
more than 0.13 mm (0.005 in), a new metering gear
set must be used.
RCPH10TLB283ABL 3
Next operation:
Power steering control valve - Assemble (41.200)
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Power steering control valve - Assemble

Prior operation:
Power steering control valve - Inspect (41.200)
1. Install the sleeve into the body.
RCPH10TLB261ABL 1
2. Put the “O” ring of the two piece seal on the recessed
tip of the plunger.
RCPH10TLB262ABL 2
3. Place the seal cup onto the recessed tip of the

plunger.
RCPH10TLB263ABL 3
4. Press the seal cup into the “O” ring.
RCPH10TLB264ABL 4
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5. Lubricate the seal with hydraulic oil.
RCPH10TLB265ABL 5
6. Install the plunger into the bore of the sleeve.
RCPH10TLB266ABL 6
7. Push the plunger into the sleeve until it bottoms out,

remove the special tools.
RCPH10TLB267ABL 7
8. Inspect the seal to make sure that it is seated prop-

erly in the body.
RCPH10TLB268ABL 8
NOTE: Seal and “O” ring must both be within shaft seal counterbore of the housing.
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9. Install the seal in the gland so that the lip is toward

the outside of the body. Drive the seal into the gland
until the seal stops moving.
RCPH10TLB269ABL 9
10. Use clean hydraulic oil to lubricate the inside of the

sleeve.
11. Use clean hydraulic oil to lubricate the outside of the
spool.
12. Install the spool in the sleeve. The spool must be
installed straight into the sleeve. Turn the spool in
both directions as the spool is pushed into the sleeve.
RCPH10TLB071ABL 10
13. There are four centering springs and three spacers.
RCPH10TLB258ABL 11
14. Insert the spring spacers and springs one at a time

into the spool and sleeve.
RCPH10TLB270ABL 12
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15. Place the spring retainer onto the sleeve.
RCPH10TLB271ABL 13
16. Work the retaining ring into place over the springs.
RCPH10TLB272ABL 14
17. Install the inner thrust washer, the thrust bearing, and
the outer thrust washer on the spool.
RCPH10TLB273ABL 15
18. Put the drive shaft into the spool.
RCPH10TLB274ABL 16
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19. Align the holes for the sleeve, spool, and drive shaft.
Press the pin into the sleeve until it is flush with the
sleeve.
RCPH10TLB275ABL 17
20. Find the port with the screw insert, install the ball and
roll pin for the manual steering check valve.
RCPH10TLB276ABL 18
21. Install the anti cavitation balls, pins, and springs into
the holes that were marked during disassembly.
RCPH10TLB277ABL 19
22. Assembly the steering control unit in a vertical po-

sition. The pin can move out of the sleeve and the
spool. If the pin moves out of the sleeve and the
spool, the pin can keep the sleeve and the spool from
being pushed into the body.
RCPH10TLB278ABL 20
NOTE: The diagram shows the steering control in a horizontal position, assemble steering control unit in a vertical
position, the pin that links the sleeve, spool, and driver could possibly slip and lock the parts in the housing.
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23. Install a new O-ring in the groove in the body, place

the spacer on the body. Put a new O-ring in the
spacer.
RCPH10TLB279ABL 21
24. Align the timing mark on the drive shaft with a valley
of the gerotor.
RCPH10TLB280ABL 22
25. Align the marks made during disassembly, install the

gerotor spacer.
RCPH10TLB281ABL 23
26. Install a new O-ring in the gerotor spacer. Install the

end plate on the metering gear set. Align the holes
in the end plate with the holes in the stator.
RCPH10TLB282ABL 24
27. Torque the cap screws to a torque of 11 - 17 N·m

(100 - 150 lb in) in the sequence shown. Then final
torque the cap screws to a final torque of 25 - 31 N·m
(225 - 275 lb in) in the sequence shown.
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RCPH10TLB003BAM 25
28. Assembled unit should rotate smoothly.
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Steering circuit relief valve - Pressure test - 580N only

Checking the pressure setting of the relief valve 580N
hoe in the transport position and lower the loader
the oil, do the following steps:
A. With the engine running at full throttle, hold the
loader control lever in the rollback position for
15 s.
B. Put the loader control lever in the neutral posi-
tion for 15 s.
3. See the illustration below. Use a pressure gauge with
a capacity of at least 276 bar (4000.0 psi). Connect
the pressure gauge to the quick is connect fitting at
the test port. The quick disconnect fitting is located
on the pump at the rear of the transmission.
4. With the engine running at full throttle, turn and hold
the steering wheel all the way to the right or to the left
and read the gauge. Make a record of the reading.
5. Decrease the engine speed to low idle for two min-
utes and stop the engine.
6. Compare the reading with the specification Hy-
draulic control components - General specifica-
tion (41.200) If the reading is not correct, repair or
replace the steering control valve.
47365539 08/07/2012
41.200 / 33
RCPH10TLB014FAM 1
(1) To inlet of loader control valve (3) Hydraulic pump 580N

(2) Test port 1
47365539 08/07/2012
41.200 / 34
Steering circuit relief valve - Pressure test - 580SN, 580SN WT and

590SN machines only
Checking the pressure setting of the relief valve 580SN, 580SN WT and 590SN machines
hoe in the transport position and lower the loader
the oil, do the following steps:
A. With the engine running at full throttle, hold the
loader control lever in the rollback position for
15 s.
B. Put the loader control lever in the neutral posi-
tion for 15 s.
3. See illustration. Use a pressure gauge with a ca-
pacity of at least 276 bar (4000.0 psi). Connect the
pressure gauge to the quick disconnect fitting that
was installed at “D” port.
4. With the engine running at full throttle, turn and hold
the steering wheel all the way to the right or to the left
and read the gauge. Make a record of the reading.
5. Decrease the engine speed to low idle for two min-
utes and stop the engine.
6. Compare the reading with the specification Hy-
draulic control components - General specifica-
tion (41.200). If the reading is not correct, repair or
replace the steering control valve.
NOTE: A Tee connection will have to be installed at the “D” port on the loader valve for steering pressure tests.
RCPH10TLB285ABL 1
47365539 08/07/2012
41.200 / 35
Index
Steering - 41

Hydraulic control components - Drawing - Optional comfort steering control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Hydraulic control components - Drawing - Steering control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Hydraulic control components - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic control components - General specification - Rotor and stator clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic control components - General specification - Steering relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic control components - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic control components - Special tools - Pressure fitting kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Hydraulic control components - Special tools - Rotor and stator clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Power steering control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Power steering control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Power steering control valve - Exploded view - 580N, 580SN, 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power steering control valve - Exploded view - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power steering control valve - Exploded view - Comfort steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power steering control valve - Exploded view - Steering control valve - Standard Steering . . . . . . . . . . . . . . . . . . 11
Power steering control valve - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power steering control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power steering control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power steering control valve - Sectional view Optional Comfort Steering Control Valve . . . . . . . . . . . . . . . . . . . . . 13
Power steering control valve - Sectional view Standard Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Steering circuit relief valve - Pressure test - 580N only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Steering circuit relief valve - Pressure test - 580SN, 580SN WT and 590SN machines only . . . . . . . . . . . . . . . . . 35
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41.200 / 36
Steering - 41
Cylinders - 216
580N
580SN WT
580SN
590SN
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41.216 / 1
Contents
Steering - 41
Cylinders - 216
TECHNICAL DATA
Power steering cylinder

FUNCTIONAL DATA

Exploded view - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE

Remove - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Install - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remove - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Check - Piston packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Disassemble - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inspect - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Assemble - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Disassemble - Four wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Inspect - Four wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Assemble - Four wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
47365539 08/07/2012
41.216 / 2
Steering - Cylinders
Power steering cylinder - General specification

Four wheel drive steering cylinder mounting screws 120 N·m (89 lb ft)
Two wheel drive steering cylinder mounting screws 335 N·m (247 lb ft)
47365539 08/07/2012
41.216 / 3
Power steering cylinder - Exploded view - Two wheel drive steering

cylinder
1. Left end cap
2. Seals
3. Piston shaft
4. O-rings
5. Tube
6. O-rings
7. Right end cap
8. Piston
47365539 08/07/2012
41.216 / 4
RCPH10TLB068GAL 1
47365539 08/07/2012
41.216 / 5
Power steering cylinder - Remove - Two wheel drive machines

1. Clean the hose connection at the steering cylinder.
2. Put and identification tag on one of the hoses.
3. Disconnect the hoses from the steering cylinder and
cap the fittings and plug the hoses.
4. Loosen and remove the tie rod end.
RCPH10TLB238ABL 1
5. Remove the mounting bolts for the cylinder, remove

the steering cylinder from the axle.
RCPH10TLB237ABL 2
Next operation:
Power steering cylinder - Install (41.216)
47365539 08/07/2012
41.216 / 6
Power steering cylinder - Install - Two wheel drive machines

Prior operation:
Power steering cylinder - Remove (41.216)
1. Install the steering cylinder on the axle and install the

bolts.
2. Torque the bolts to 335 N·m (247 lb ft).
3. Install the tie rod ends and torque to 165 N·m (122
lb ft).
system.
7. Stop the engine and check for oil leaks.
8. Check the level of the oil in the reservoir and add oil
as required.
9. Grease the pins for the steering links.
10. Check and adjust the toe-in according to the instruc-
tions in Powered front axle - Assemble (25.100).
47365539 08/07/2012
41.216 / 7
Power steering cylinder - Remove - Four wheel drive machines
NOTE: The following photographs show the steering cylin-

der being removed from the axle with the axle removed
from the machine. It is not necessary to remove the axle
from the machine to remove the steering cylinder.
1. Clean the hose connections and the steering cylin-
der.
2. Fasten an identification tag to one of the hoses to the
steering cylinder.
3. Disconnect the hoses from the steering cylinder. In-
stall a plug is each hose and a cap on each fitting.
NOTE: Some of the photo may look different than your
machine. The procedure is the same.
4. Loosen the nut several turns. Do not remove the nut
at this time.
RCPH10TLB301ABL 1
5. Install the CAS10486 puller and tighten the screw to

loosen the ball joint.
6. Remove the nut and remove the ball joint from the
arm.
RCPH10TLB302ABL 2
7. Repeat steps 4, 5 and 6 for the other end of the axle.
47365539 08/07/2012
41.216 / 8
8. Install the 380100091 or 380100092 tool on the flats

of the piston rod and install a wrench on the tie rod.
Prevent the piston rod from turning and loosen the
tie rod.
RCPH10TLB303ABL 3
9. Remove the tie rod and ball joint assembly from the
piston rod.
10. Loosen and remove the bolts that fasten the steering
cylinder to the axle.
RCPH10TLB286ABL 4
11. A hose fitting will be installed in your steering cylin-

der. Remove the hose fitting.
RCPH10TLB287ABL 5
12. Hit the steering cylinder with a soft hammer to drive

the steering cylinder out of the axle.
RCPH10TLB288ABL 6
13. Remove the steering cylinder from the axle.
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Next operation:
Power steering cylinder - Install (41.216)
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41.216 / 10
Power steering cylinder - Install - Four wheel drive machines

Prior operation:
Power steering cylinder - Remove (41.216)
1. Install the steering cylinder in the axle.

2. Install the bolts that fasten the steering cylinder to the
axle. Tighten the bolts to 120 N·m (89 lb ft).
RCPH10TLB286ABL 1
3. Start the ball joint assembly and tie rod onto the pis-
ton rod.
4. Install the 380100091 or 380100092 tool on the
flats of the piston rod and install a wrench on the tie
rod. Prevent the piston rod from turning the tie rod.
Tighten the tie rod to a torque of 300 N·m (221 lb ft).
RCPH10TLB304ABL 2
5. Install the ball joint in the arm.
RCPH10TLB302ABL 3
47365539 08/07/2012
41.216 / 11
6. Install the nut on the ball joint and tighten the nut to
165 N·m (122 lb ft) for the 580N, 580SN and 580SN
+. Tighten to 220 N·m (162 lb ft) for the 590SN.
RCPH10TLB305ABL 4
7. Repeat steps 5, 6, and 7 for the other end of the axle.

8. Connect the hoses to the fittings in the steering cylin-
der.
system.
11. Stop the engine and check for oil leaks.
12. Check the level of the oil in the reservoir and add oil
as required.
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Power steering cylinder - Check - Piston packing

Checking piston packing for the steering cylinder
1. Apply the parking brake and lower the loader bucket
to the floor.
stop the engine.
3. Disconnect the hose at the left side of the steering
cylinder.
4. Install a plug in the hose.
5. Start the engine and run the engine at full throttle.
continue to turn the steering wheel to the right while
another person checks for leakage at the open fitting.
7. If there is constant leakage, the piston packing is
damaged and must be repaired.
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Power steering cylinder - Disassemble - Two wheel drive steering

cylinder
1. Clean the outside of the steering cylinder.
2. Fasten the steering cylinder in a vise or other hold-
ing equipment. Be careful to prevent damage to the
tube. (5)
3. Remove the right (7) and left (1) end caps.
4. Pull the piston rod (3) out of the tube (5).
5. Remove and discard all O-rings and seals.
RCPH10TLB068GAL 1
Next operation:
Power steering cylinder - Inspect (41.216)
47365539 08/07/2012
41.216 / 14
Power steering cylinder - Inspect - Two wheel drive steering cylinder

Prior operation:
Power steering cylinder - Disassemble (41.216)

age. If there is damage to the tube (5), a new steering
cylinder must be used.
3. Verify that the piston rod (3) is straight. If the piston
rod (3) is not straight, a new steering cylinder must
be used.
4. Inspect the piston (8) for damage and wear. If the
piston (8) is damaged, or worn, a new steering cylin-
der must be used.
5. Remove the small scratches on the piston rod (3) and
inside the tube (5) with emery cloth of medium grit.
Use emery cloth with a rotary motion.
6. Inspect both ends of the tube (5) for sharp edges that
will cut the end cap O-rings (1) and (7) and remove
the sharp edges as necessary.
7. Inspect all components for rust. Clean and remove
rust as necessary.
RCPH10TLB068GAL 1
Next operation:
Power steering cylinder - Assemble (41.216)
47365539 08/07/2012
41.216 / 15
Power steering cylinder - Assemble - Two wheel drive steering

cylinder
Prior operation:
1. Install a new seals and O-rings.

2. Fasten the tube (5) in the vise or other holding equip-
3. Lubricated the bore of the tube (5) with clean oil.
4. Lubricate the O-rings (6) on both end caps (1) and
(7) and the bore of both end caps (1) and (7) with
clean oil.
5. Lubricate the piston (3) with clean oil.
6. Push the piston rod assembly (3) straight into the
tube (5).
7. Carefully start the end caps (1) and (7) onto the pis-
ton (3).
8. Verify the ports in both glands (8) are installed cor-
rectly and drive the end caps (1) and (7) into the tube
(5).
RCPH10TLB068GAL 1
47365539 08/07/2012
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Power steering cylinder - Disassemble - Four wheel drive steering

cylinder
1. Remove the tie rod ball joint assembly.
2. Fasten the tube in a vise or other holding equipment.
Do not damage the tube.
RCPH10TLB290ABL 1
3. Use a soft faced hammer and separate the gland

from the tube.
RCPH10TLB291ABL 2
4. Remove the gland from the piston rod assembly.
RCPH10TLB292ABL 3
5. Use a soft faced hammer and drive the piston against

the gland, remove the gland from the tube.
RCPH10TLB293ABL 4
47365539 08/07/2012
41.216 / 17
6. Pull the piston rod assembly straight out of the tube

to prevent damage to the tube.
RCPH10TLB294ABL 5
7. Remove the gland from the piston rod.
RCPH10TLB295ABL 6
8. Remove the wiper and the seal from the gland. Re-
move the seal ring from the gland. Repeat the pro-
cedure for the other gland.
RCPH10TLB296ABL 7
9. Remove the seals from the piston rod assembly.
RCPH10TLB297ABL 8
Next operation:
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Power steering cylinder - Inspect - Four wheel drive steering

cylinder
Prior operation:
Power steering cylinder - Disassemble (41.216)
1. Discard the parts that were removed from the glands

and piston rod assembly.
3. Inspect the gland, piston rod assembly and the tube
for damage and wear. These parts are not serviced
separately, if these parts need to be replaced, a new
steering cylinder must be used.
Next operation:
Power steering cylinder - Assemble (41.216)
47365539 08/07/2012
41.216 / 19
Power steering cylinder - Assemble - Four wheel drive steering

cylinder
1. Install a new seal in the grooves of the piston rod
assembly.
RCPH10TLB299ABL 1
2. Install a new seal in the gland. The lip of the seal

must be toward the inside of the gland.
RCPH10TLB297ABL 2
3. Install a new wiper in the gland. The lip of the wiper

must be toward the outside of the gland.
RCPH10TLB298ABL 3
4. Install a new seal ring in the groove on the gland.

5. Lubricate the piston seals with clean oil.
47365539 08/07/2012
41.216 / 20
6. Fasten the tube in a vise with soft jaws. Start the

piston rod assembly into the tube, be careful not to
damage the seals.
RCPH10TLB294ABL 4
7. Push the piston rod assembly all the way into the
tube, use a soft faced hammer and drive the gland
into the tube.
8. Lubricate the wiper, seal, and seal ring on the gland
with clean oil.
9. Install the gland on the piston rod assembly and push
the gland against the tube, use a soft faced hammer
and drive the gland into the tube.
RCPH10TLB292ABL 5
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Index
Steering - 41
Cylinders - 216
Power steering cylinder - Assemble - Four wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Power steering cylinder - Assemble - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power steering cylinder - Check - Piston packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power steering cylinder - Disassemble - Four wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Power steering cylinder - Disassemble - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power steering cylinder - Exploded view - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Power steering cylinder - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Power steering cylinder - Inspect - Four wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Power steering cylinder - Inspect - Two wheel drive steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power steering cylinder - Install - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Power steering cylinder - Install - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Power steering cylinder - Remove - Four wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Power steering cylinder - Remove - Two wheel drive machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
47365539 08/07/2012
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PRINTED IN U.S.A.
47365539 08/07/2012
EN
SERVICE MANUAL
Wheels
580N
580SN WT
580SN
590SN
47365539 08/07/2012
44
Contents
Wheels - 44
Front wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.511

580N , 580SN WT , 580SN , 590SN
Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.520

580N , 580SN WT , 580SN , 590SN
47365539 08/07/2012
44
Wheels - 44
Front wheels - 511
580N
580SN WT
580SN
590SN
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44.511 / 1
Contents
Wheels - 44
Front wheels - 511
TECHNICAL DATA
Front wheels
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front wheels
Torque - Front wheel mounting nut torque procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tire pressure - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tire pressure - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tire pressure - 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Front wheels
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
47365539 08/07/2012
44.511 / 2
Wheels - Front wheels
Front wheels - General specification

NOTE: When the machine is new or when a wheel is removed for service, check the wheel nut or bolt torques every
10 hours of operation until the wheel nuts or bolts remain tight.
NOTE: The rear wheel mounting nuts on this machine are metric. Use only the mounting nuts shown in the parts
catalog for this machine.
NOTE: Check the torque with a dial or click wrench. If the
nut does not move on the following torques, it is tight and
does not need re-torqued:
Front wheel, two wheel 156 N·m (115.1 lb ft)

drive
Front wheel, four wheel 251 N·m (185.1 lb ft)
drive
Rear wheel, mounting nuts 305 N·m (225.0 lb ft)
Front wheels - Torque

Front wheel, two wheel drive 156 - 203 N·m (115.1 - 149.7 lb ft)
Front wheel, four wheel drive 251 N·m (185.1 lb ft)
Rear wheel, mounting nuts 305 N·m (225.0 lb ft)
47365539 08/07/2012
44.511 / 3
Front wheels - Torque - Front wheel mounting nut torque procedure

1. Install all eight (8) mounting nuts. Tighten all mount-
ing nuts, in the sequence shown, until the wheel is snug
against the axle hub.
2. Tighten the mounting nuts, in the sequence shown, to
a torque of 122 Nm (90 pound-feet)
3. Then turn each nut in the tightening direction, in the
sequence shown, an additional 90 degrees to set the re-
quired pre-load on the front wheel mounting nuts.
RCPH10TLB610AAL 1
Front wheels - Tire pressure - 580N and 580SN only

11L x 16 (2wd), 10 PR, F3 52 psi (358 kPa, 3.6 bar)
4WD - 12 x 16.5 (4wd), 8 PR, Lug 50 psi (345 kPa, 3.4 bar)
Front wheels - Tire pressure - 580SN-WT only

12.5/80x18 42wd), 10 PR 4.1 bar (59.5 psi)
Front wheels - Tire pressure - 590SN only

14.5 x 17.5 (2wd), 10 PR, F3 40 psi (276 kPa, 2.8 bar)
14 x 17.5 (4wd), 10PR, Lug 55 psi (380 kPa, 3.8 bar)
47365539 08/07/2012
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Front wheels - Remove

1. Raise and support the backhoe.
RCPH11TLB119AAM 1
2. Remove hardware.
RCPH11TLB135AAM 2
3. Remove the wheel.
RCPH11TLB136AAM 3
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Front wheels - Install

1. Carefully position the wheel onto the hub.
RCPH11TLB135AAM 1
2. Tighten the eight mounting nuts in sequence until the

wheel is snug against the axle hub.
3. Tighten the nuts in sequence to a torque of 122 N·m
(90 lb ft)
4. Turn the nuts in sequence an additional 90 ° to set
the preload.
5. Tighten the nuts in sequence to a torque of
Two Wheel Drive Machines — 156 - 203 N·m (115 - 150 lb
ft).
Four Wheel Drive Machines — 251 N·m (185 lb ft).
RCPH10TLB074AAF 2
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Index
Wheels - 44
Front wheels - 511

Front wheels - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front wheels - Tire pressure - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front wheels - Tire pressure - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front wheels - Tire pressure - 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Front wheels - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Front wheels - Torque - Front wheel mounting nut torque procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Wheels - 44
Rear wheels - 520
580N
580SN WT
580SN
590SN
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Contents
Wheels - 44
Rear wheels - 520
TECHNICAL DATA
Rear wheel
Torque - Rear wheel mounting nut torque procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tire pressure - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tire pressure - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tire pressure - 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Rear wheel
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Wheels - Rear wheels
Rear wheel - Torque - Rear wheel mounting nut torque procedure

1. Install all ten (10) wheel mounting nuts. Tighten all mounting nuts, in the sequence shown, until the wheel is snug
against the axle hub.
2. Tighten the mounting nuts, in the sequence shown, to a torque of 136 Nm (100 pound-feet).
3. Then turn the mounting nuts again, in the sequence shown, to a torque of 271 Nm (200 pound-feet).
4. Then turn each mounting nut in the tightening direction, in the sequence shown, an additional 30 degrees to set
the required pre-load on the rear wheel mounting nuts.
RCPH10TLB611AAL 1
Rear wheel - Tire pressure - 580N and 580SN only

16.9 x 28, 10 PR, R4 32 psi (220 kPa, 2.2 bar)
17.5Lx24, 10 PR, R4 32 psi (220 kPa, 2.2 bar)
19.51L x 24, 10 PR, R4 28 psi (193 kPa, 2.3 bar)
Rear wheel - Tire pressure - 580SN-WT only

21L x 24, 10 PR 26 psi (179 kPa, 1.8 bar)
Rear wheel - Tire pressure - 590SN only

21 L x 24, 10 PR, R4 26 psi (179 kPa, 1.8 bar)
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Rear wheel - Remove

1. Raise and support the backhoe.
RCPH11TLB138AAM 1
2. Remove hardware.
RCPH11TLB138AAM 2
3. Remove the wheel.
RCPH11TLB120AAM 3
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Rear wheel - Install

1. Carefully position the wheel onto the hub.
RCPH11TLB138AAM 1
2. Tighten the ten mounting nuts in sequence until the

wheel is snug against the axle hub.
(100 lb ft).
4. Tighten the nuts a second time, in sequence to a
torque of 271 N·m (200 lb ft).
5. Turn the nuts in sequence an additional 30 ° to set
the preload.
(225 lb ft).
RCPH10TLB075AAF 2
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Index
Wheels - 44
Rear wheels - 520

Rear wheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear wheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Rear wheel - Tire pressure - 580N and 580SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear wheel - Tire pressure - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear wheel - Tire pressure - 590SN only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Rear wheel - Torque - Rear wheel mounting nut torque procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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PRINTED IN U.S.A.
47365539 08/07/2012
EN
SERVICE MANUAL
Cab climate control
580N
580SN WT
580SN
590SN
47365539 08/07/2012
50
Contents
Cab climate control - 50
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.200

580N , 580SN WT , 580SN , 590SN
47365539 08/07/2012
50
CONSUMABLES INDEX
Consumable IU PAGE
CNH Refrigerant HFC-134a Air conditioning - Pressure test and temperature testing 50.200 / 20
CNH PAG Oil Air-conditioning compressor - Check - Oil level check 50.200 / 27
CNH PAG Oil Expansion valve - Test Expansion valve testing 50.200 / 42
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50
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50
Air conditioning - 200
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
Air conditioning
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUNCTIONAL DATA
Air conditioning
Overview - Safety procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Overview - Safety procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air-conditioning compressor
Exploded view - Clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Expansion valve
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SERVICE
Air conditioning
Charging - Air conditioner system evacuation and recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pressure test and temperature testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air-conditioning compressor
Adjust - Belt check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Check - Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Disassemble - Clutch disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Assemble - Clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Air-conditioning condenser
Check - Condenser, receiver-drier, and tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Expansion valve
Test Expansion valve testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Air-conditioning evaporator
Remove Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
47365539 08/07/2012
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CONSUMABLES INDEX
Consumable IU PAGE
CNH Refrigerant HFC-134a Air conditioning - Pressure test and temperature testing 50.200 / 20
CNH PAG Oil Air-conditioning compressor - Check - Oil level check 50.200 / 27
CNH PAG Oil Expansion valve - Test Expansion valve testing 50.200 / 42
47365539 08/07/2012
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Cab climate control - Air conditioning
Air conditioning - General specification

Air conditioning system refrigerant capacity 1.48 kg (3.26 lb)
Air conditioning - Special tools

OEM 1415 Belt Tension Tool
299L7C 1
OEM 1415 Refrigerant Recovery, Recycling and Charging

Station
In the USA and Canada order Service Tool from:
OTC Division/ SPX Corporation
655 Eisenhower Drive
Owatonna, MN. 55060
Phone: 1-800-533-0492
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OEM-1437 Electronic Leak Detector
Safety Goggles - Obtain locally
RCPH10TLB677AAL 4
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Air conditioning - Overview - Safety procedures

ATTENTION: Only authorized technicians certified by an
approved training and certification organization may ser-
vice or repair motor vehicle or mobile air conditioning sys-
tems. It is mandatory that all refrigerant be recovered and
recycled when removed from a system during servicing.
Refrigerant HFC134a is the most stable, and easiest to

work with of the refrigerants now used in air conditioner
systems. Refrigerant HFC134a does not contain any
chlorofluorocarbons (CFC’s) which are harmful to the
earth’s ozone layer.
Safety procedures must be followed when working with

Refrigerant HFC134a to prevent possible personal injury.
1. Always wear safety goggles when doing any service
work near an air conditioner system. Liquid refrig-
erant getting into the eyes can cause serious injury.
Do the following if you get refrigerant near or in your
eyes:
A. Flush your eyes with water for 15 min minutes.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may cause
frostbite. Open the fittings carefully and slowly when
it is necessary to service the air conditioner system.
Your skin must be treated for frostbite or a physician
must be seen if you get refrigerant on your skin.
3. Keep refrigerant containers in the correct upright
position. Always keep refrigerant containers away
from heat and sunlight. The pressure in a container
will increase with heat.
4. Always reclaim refrigerant from the system, if you
are going to weld or steam clean near the air condi-
tioner system.
5. Always check the temperature and pressure of the
air conditioner system before reclaiming refrigerant
and when you test the system.
6. Dangerous gas can form when refrigerant comes in
contact with an open flame. Never permit fumes to
be inhaled.
7. Never leak test with compressed air or flame testers.
Tests have indicated that compressed mixtures of
HFC134a and air can form a combustible gas.
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Air conditioning - Overview - Operation

The refrigerant circuit of the air conditioning system contains five major components: compressor, condenser, re-
ceiver-drier, expansion valve and evaporator. These components are connected by tubes and hoses and operate as
a closed system. The air conditioner system is charged with HFC134a refrigerant.
The compressor receives the refrigerant as a low pressure gas. The compressor then compresses the refrigerant
and sends it in the form of a high pressure gas to the condenser. The air flow through the condenser then removes
the heat from the refrigerant. As the heat is removed the refrigerant changes to a high pressure liquid.
The high pressure refrigerant liquid then flows from the condenser to the receiver drier. The receiver-drier is a con-
tainer filled with moisture removing material, which removes any moisture that may have entered the air conditioner
system in order to prevent corrosion of the internal components of the air conditioner system.
The refrigerant still in a high pressure liquid form, then flows from the receiver-drier to the expansion valve. The
expansion valve then causes a restriction in flow of refrigerant to the evaporator core.
As the refrigerant flows through the evaporator core the refrigerant is heated by the air around and flowing through
the evaporator fins. The combination of increased heat and decreased pressure causes the air flow through the
evaporator fins to become very cool and the liquid refrigerant to become a low pressure gas. The cooled air then
passes from the evaporator to the cab for the operator’s comfort.
The electrical circuit of the Air Conditioning System consists of a fan speed control, temperature control, three (3) mini
relays, two (2) 10 amp circuit breakers, two (2) fan motors, a blower motor, blower resistor, compressor clutch, low
pressure switch, high pressure switch, and warning light.
RCPH10TLB137GAL 1
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1. Expansion valve 4. Condenser

2. Evaporator 5. Receiver-drier
3. Compressor
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Air conditioning - Overview - Safety procedures

ATTENTION: Only authorized technicians certified by an approved training and certification organization may service
or repair motor vehicle or mobile air conditioning systems. It is mandatory that all refrigerant must be recovered and
recycled when removed from a system during servicing.
Refrigerant HFC-134a is the most stable and easiest to
work with of the refrigerants now used in air conditioning
systems. Refrigerant HFC-134a does not contain chlo-
rofluorocarbons (CFC’s) which are harmful to the Earth’s
ozone layer.
Safety procedures must be followed when working with
refrigerant HFC-134a to prevent possible personal injury.
1. Always wear safety goggles when doing any service
work near an air conditioner system. Liquid refrig-
erant getting into the eyes can cause serious injury.
Do the following if you get refrigerant near or in your
eyes:
A. Flush your eyes with water for 15 min.
B. See a physician immediately.
2. A drop of liquid refrigerant on your skin may cause
frostbite. Open the fittings carefully and slowly when
it is necessary to service the air conditioner system.
Your skin must be treated for frostbite or a physician
must be seen if you get refrigerant on your skin.
3. Keep refrigerant containers in the correct upright
position. Always keep refrigerant containers away
from heat and sunlight. The pressure in a container
will increase with heat.
4. Always reclaim refrigerant from the system, if you
are going to weld or steam clean near the air condi-
tioner system.
5. Always check the temperature and pressure of the
air conditioner system before reclaiming refrigerant
and when you test the system.
6. Dangerous gas can form when refrigerant comes in
contact with an open flame. Never permit fumes to
be inhaled.
7. Never leak test with compressed air or flame testers.
Tests have indicated that compressed mixtures of
HFC-134a and air can form a combustible gas.
8. Always reclaim refrigerant from the system before
removing any air conditioning component.
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Air-conditioning compressor - Exploded view - Clutch assembly
RCPH10TLB001EAL 1
1. Compressor 5. Bearing dust cover

2. Coil assembly 6. Front plate
3. Pulley 7. Shim(s)
4. Bearing 8. Dust cover
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Expansion valve - Exploded view
RCPH10TLB036GAL 1
1. Evaporation core 4. O-rings 7. Pressure switch

2. Expansion valve 5. Suction tube 8. Control switch
3. O-rings 6. Pressure tube
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Air conditioning - Charging - Air conditioner system evacuation

and recharging
NOTICE: Replace the receiver-drier if one or more of the following conditions occurs before you remove the air and
moisture from the system.
A. The system has been opened for service be-

fore.
B. Receiver-drier has operated two or more years.
C. Disassembly of compressor shows small par-
ticles of moisture removing material (gold or
brown particles).
D. Large system leak (broken hose, break in line).
E. Too much air or moisture in system.
F. Removal of compressor caused the system to
be open (uncapped) longer than 5 min.
1. With the charging station manifold gauge valves in
the closed position, connect the hoses from the test
gauges to the service ports as follows:
A. Connect the hose from the low pressure gauge

to the port on the suction hose.
B. Connect the hose from the high pressure
gauge to the port on the discharge hose.
C. Turn in both thumbscrews to depress the ser-
vice valves.
Removal of air and moisture from the system is necessary
after the refrigerant has been removed after the system
has been opened for maintenance. Air enters the system
when the system is opened. Air has moisture that must be
removed to prevent damage to the system components.
NOTE: The pump on the reclamation unit will not pull a sufficient vacuum to remove air and moisture.
Air and moisture are removed from the system by a vacuum
pump. A vacuum pump is the only equipment made to
lower the pressure enough to change the moisture to vapor
that can be removed from the system.
NOTE: Refer to the vacuum pump manufacturer’s user manual for additional information.
2. Connect the main power plug to a 115 V AC outlet.
Move the main power switch to the ON position. If
program and vacuum do not appear at the top of the
display press the vacuum key. Program a minimum
of 45 min and press the Enter key. The display will
flash once indicating the programmed data has been
accepted
RCPH10TLB660AAL 1
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3. Press the Charge key. “Program” and “Charge” will

appear on the display.
RCPH10TLB663AAL 2
4. Program 3.75 lb and press the enter key. The display

will flash once indicating the programmed data has
been accepted.
RCPH10TLB661AAL 3
5. Fully open the low and high pressure valves.
RCPH10TLB662AAL 4
6. Open the red (vapor) and blue (liquid) valves on the

tank.
RCPH10TLB656AAL 5
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7. Press the Vacuum key. “Automatic” will appear on

the display. Vacuum will appear on the display and
after a slight delay, the vacuum pump will start. The
display will show the amount of time programmed
and begin a countdown to zero.
When the programmed time has elapsed, an automatic
hold occurs. Check the low pressure gauge to see that
the A/C system maintains a 28 - 29-1/2 in Hg of mercury
(Hg). The low pressure gauge must not increase faster
than 1 in of mercury (Hg) in 10 min . A previously charged,
leak-free system will leach refrigerant from compressor oil
and raise system pressure under vacuum. If the system
will not hold vacuum, a leak exists that must be corrected
before recharging can begin. RCPH10TLB665AAL 6
8. Press the charge key to begin refrigerant charging.

“Automatic” and “Charge” will appear on the display.
The display shows the programmed amount and
counts down to zero as charging proceeds. When
charging is completed, the display shows “CPL”.
RCPH10TLB661AAL 7
9. Completely close the high and low pressure manifold

valves.
RCPH10TLB662AAL 8
ATTENTION: Check the OEM equipment manual before performing Step 10 to avoid damaging the recovery unit.
The pressure reading should be obtainable with valves closed. Damage may occur if the machine is started with the
valves accidently open or if either or both valves are opened while the A/C system is operating.
10. Start the engine and run at 1500 RPM. Operate the
air conditioner system at maximum cooling setting
and blower speed with the doors and windows open.
NOTE: The compressor will not operate if the system pres-
sure is too low or too high. The pressure indicator lamp will
illuminate when the relay is actuated by a low or high pres-
sure and the compressor clutch will disengage. To restart
the compressor, the air conditioner control or blower switch
must be turned to the OFF position and then to the ON po-
sition.
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11. Observe the pressure gauge readings to determine

that the correct amount of refrigerant has entered
the system. See Temperature Pressure Chart for
temperature and pressure variations.
RCPH10TLB664AAL 9
12. Stop the engine, close any open valves and carefully
remove the manifold gauge hoses.
13. Install the caps on the service ports on the suction
and discharge hoses.
RCPH10TLB042AAL 10
Pressure temperature chart

Ambient Normal low pressure Normal high pressure Air louver (behind seat)
temperature indication indication maximum temperature
27 °C (81 °F) 0.62 - 0.83 bar (9 - 12 psi) 10 - 11.5 bar (145 - 167 psi) 14 °C (57 °F)
32 °C (90 °F) 0.76 - 1.04 bar (11 - 15 psi) 13.1 - 14.5 bar (190 - 210 psi) 18 °C (64 °F)
43 °C (109 °F) 1.93 - 2.14 bar (22 - 24 psi) 20 - 21.4 bar (290 - 310 psi) 25 °C (77 °F)
The pressure-temperature chart is based on the fol-

lowing conditions:
1. Engine operating at 1500 RPM.
2. No engine load.
3. Fan speed control in maximum position (full
clockwise) and all louvers open.
4. Cab temperature control set to maximum cool-
ing (full counterclockwise).
5. Both cab doors open.
6. All panels and access doors installed and
closed.
7. Cab filters clean and installed.
8. Heater valve at engine closed.
9. Measurements taken 15 min after start-up.
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Air conditioner system refrigerant recovery

Recovered refrigerant passes through an oil separator and
a filter-drier before entering the refrigerant tank. The mois-
ture indicator will turn green when dry refrigerant passes
over it.
If possible, run the air conditioning system for ten minutes
before starting the recovery process. Turn the system off
before proceeding.
1. Clean the external surfaces of the compressor and
hoses. Remove the caps from the service ports on
the suction and pressure hoses.
2. With the charging station manifold gauge valves in
the closed position, connect the hoses from the test
gauges to the service ports.
Connect the hose from the low pressure gauge to the
port on the suction hose. Turn in valve depressor
Connect the hose from the high pressure gauge to
the port on the discharge hose. Turn in valve de-
pressor.
RCPH10TLB042AAL 11
3. Open the high and low valves.
RCPH10TLB662AAL 12
4. Make certain the refrigerant tank gas and liquid

valves are open.
RCPH10TLB656AAL 13
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5. Connect the main power plug to a 115 V AC outlet.

Move the main power switch to the ON position and
depress the recovery start switch.
The compressor will shut OFF automatically when
recovery is complete. Wait for 5 min and observe
the manifold pressure gauges for a pressure rise.
If pressure rises above 0 bar (0 psi), depress the
hold/cont switch. Then wait for the compressor to
automatically shut OFF.
RCPH10TLB660AAL 14
6. Drain the oil separator of the A/C system oil. Open

the air purge valve long enough to let some of the
compressor discharge pressure back into the sepa-
rator.
RCPH10TLB657AAL 15
7. Slowly open the oil drain valve and drain the oil into
the reservoir. When the oil stops draining, close the
oil drain valve completely.
RCPH10TLB658AAL 16
8. Fill the A/C compressor with fresh SP-15 PAG oil

equal to the amount in the reservoir.
RCPH10TLB659AAL 17
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9. Remove the hoses from the service ports and install

the caps.
RCPH10TLB042AAL 18
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Air conditioning - Pressure test and temperature testing

Use either a Manifold gauge set tool 380000239 or an appropriate refrigerant recovery, recycling and charging station
capable of taking high and low pressure/vacuum tests simultaneously.
Refer to the testing tool operator's manual for testing procedures before servicing the air conditioning system.
Prepare the machine for service: Park the machine and place the transmission gears in a neutral position, secure the
loader bucket in a fully raised position, turn the engine off, chock the wheels, and raise the engine hood.
Manifold Gauge Set

The manifold gauge set is the most important tool
used to service the air conditioning system. The
manifold gauge set is used to measure the high and
low pressures of the system, the correct refrigerant
charge, system diagnosis, and operating efficiency.
The manifold gauge set reads both the high (dis-
charge) and low (suction) sides at the same time,
since pressure must be compared in order to make
a diagnosis of the system's operation.
• Low pressure gauge – The low pressure gauge
is a compound gauge. Under some conditions,
air conditioning systems can change from a
pressure into a vacuum on the low side. For
this reason, it is necessary to use a compound RCPH10TLB001BAD 1
gauge that will indicate both pressure and vac-
uum.
• High pressure gauge – The high pressure
gauge is used to indicate pressures in the high
side of the system.
Refrigerant recovery, recycling and charging station

A refrigerant recover, recycling and charging station
shown is a full service air conditioning system ma-
chine. It can perform multiple procedures such as:
• Recover and recycle refrigerant.
• Charge the air conditioning system.
• High and low pressure tests.
• Remove air and condensation from the system.
RCPH10TLB655AAL 2
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Pressure and temperature test

1. Clean the external surfaces of the compressor and
tubes. Remove the caps from the service ports on
the suction (1) and pressure (2) tubes.
2. Connect an appropriate pressure testing gauge
hoses to the air conditioning system's service ports.
• Close the gauge valves and attach the low
pressure gauge hose to the suction service port
(1).
• Close the gauge valves and attach the high
pressure gauge hose to the pressure service
port (2).
RCPH10TLB042AAL 3
3. The following conditions are required for an accurate

pressure/temperature test.
• Measurements taken 15 minutes after engine
start up.
• Engine operating at 1800 RPM with no engine
load present.
• Air conditioning system charged at 1.48 kg
(3.26 lb) of CNH REFRIGERANT HFC-134A.
• A/C switch on.
• Fan speed control in maximum position and all
louvers open.
• Cab temperature control set to maximum cool-
ing (full counterclockwise position).
• All panels and component access doors in-
stalled and closed.
• Cab filters clean and installed.
• Cab doors open and back windows down.
• Heater valve closed at engine.
4. Record the following temperature and pressure read-
ings:
• Ambient temperature inside the cab and di-
rectly in front of the air louver behind the seat.
• Low and high pressure gauge readings.
5. Turn the engine off.
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39 ° Steel fan – 580N and 580SN

Ambient Normal low Normal high Air louver (behind seat)
temperature pressure indication pressure indication maximum temperature
27 °C (80.6 °F) 1.10 - 1.24 bar (16 - 18 psi) 13.1 - 14.4 bar (190 - 209 psi) 12 °C (53.6 °F)
Viscous fan – 580SN WT, 590SN and 580SN with cab convenience package
Ambient Normal low Normal high Air louver (behind seat)
temperature pressure indication pressure indication maximum temperature
6. Compare the recorded test results with the appropri-

ate chart and continue with one of the following:
• Results are not within the acceptable range –
Refer to the appropriate trouble shooting guide
based on the recorded results.
• Results are within the acceptable range – Dis-
connect the test equipment hoses and secure
the service port caps. The pressure test is
complete.
Next operation:
Air conditioning - Check (50.200)
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Air conditioning - Check

NOTE: The low pressure switch is located in the roof of the cab in the low pressure tube to the evaporator.The high
pressure switch is located at the front of the tractor and behind the grill.
1. Engine OFF, key switch ON, blower switch ON, and
temperature control switch turned fully clockwise.
Both pressure switches should remain in the open
position.
NOTE: With the engine OFF, system pressure will equalize on both sides of system to approximately 75 PSI (520
kPa) at room temperature.
2. Low pressure switch located in cab roof. Check for
12 VDC at low pressure switch with a test lamp. If
no voltage, check temperature control switch. The
low pressure switch is open whenever the pressure is
above 2 to 6 PSI (14 to 41 kPa). Below this the switch
closes and sends a signal to the relay to disengage
the compressor clutch. Check both terminals of the
low pressure switch with a test lamp. If voltage is
available at both terminals and pressure is not below
2 PSI (14 kPa), replace the switch.
RCPH10TLB667AAL 1
3. High pressure switch located at the condenser.

Check for 12 VDC at high pressure switch. If no
voltage, check temperature control switch. Check
both terminals of high pressure switch with a test
lamp. If voltage is present at both terminals and
pressure is not above 385 PSI (2 654 kPa), replace
the switch.
RCPH10TLB669AAL 2
Next operation:
Air conditioning - Check (50.200)
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Air conditioning - Check

Current Check
1. The temperature control switch is located in the in-
strument panel.
2. The temperature control switch senses evaporator
temperature and controls current flow for compressor
clutch operation.
3. The switch interrupts current flow to the clutch at 33°
F to 37° F (0.6° C to 2.8° C) and will allow the clutch to
energize at 42° to 70° F (5.6° C to 21° C) depending
on switch position.
4. If the temperature control switch malfunctions, re-
place it.
5. Remove instrument cluster to gain access to the tem-
perature control switch.
RCPH10TLB668AAL 1
6. Engine OFF, key switch ON, and blower switch ON.

7. Turn temperature control switch fully clockwise. Re-
move sensing tube from evaporator.
8. Place end of sensing tube (1) in a container (2) with
ice and water mixture.
RCPH10TLB680AAL 2
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9. When the sensing tube has cooled to the tempera-

ture of the ice and water mixture, the temperature
control switch (1)should interrupt the current flow to
the compressor.
RCPH10TLB668AAL 3
10. Check for current at temperature control switch ter-

minal with the No. 60 and No. 85 wires. Use a test
lamp connected to a good ground.
11. If current is not interrupted, replace the temperature
control switch.
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Air-conditioning compressor - Adjust - Belt check and adjustment

WARNING
Rotating parts!
The engine is running. Keep clear of rotating fans and belts.
W0275A
Check interval Every 250 hours of operation
NOTE: Check the belt tension after the first 10 hours of operation and then use the regular check interval.
Measure the compressor belt for correct tension using a
belt tension gage. Check the belt to the following specifi-
cations.
RCPH10TLB672AAL 1
Belt tension 200 - 245 N (45 - 55 lb)
To adjust the belt tension, loosen the compressor adjust-

ing bolts and pivot bolt. Apply pressure to the compressor
until the correct tension for the belt is reached. Tighten the
compressor adjusting bolts and pivot bolt.
Measure the compressor belt for correct tension using a
belt tension gage. Check the belt to the following specifi-
cations.
Belt tension 400 - 490 N (90 - 110 lb)
To adjust the belt tension, loosen the pivot bolt, loosen the
slot bolt, loosen the jam nut on the adjusting bolt. Turn
the adjusting bolt in until the proper tension for the belt is
reached. Tighten the jam nut, tighten the slot bolt, tighten
the pivot bolt.
RCPH10TLB670AAL 2
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Air-conditioning compressor - Check - Oil level check

Check the oil level in the compressor when any of the fol-
lowing has occurred:
A. Broken refrigerant hose.
B. Large refrigerant leak.
C. Compressor leak.
D. Damage to system components.
E. New compressor installed.
Use the following procedure to check the compressor oil
level.
1. Start the engine and run at 1500 RPM maximum.
Operate the air conditioner for 10 - 15 min at maxi-
mum cooling and high blower speed.
2. Stop the engine. Connect the compressor to the air
conditioner charging, recovery, and recycling station.
Discharge the system.
NOTE: Wear safety goggles when working with refrigerant.
3. Check the mounting angle of the compressor. Put
the angle gauge from the service tool set across the
flat surfaces of the two front mounting ears. Adjust
the gauge so that the bubble is between the center
marks. Read the mounting angle to the nearest de-
gree mark. Make a note of the degree reading for
reference later.
RCPH10TLB630AAL 1
4. Remove the oil filler plug.
RCPH10TLB675AAL 2
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5. Remove the dust cover and use a wrench to rotate

the clutch clockwise until the internal parts are in the
position shown above. This will permit the dipstick to
be inserted all the way.
RCPH10TLB011ACL 3
6. Put the dipstick in the oil filler hole to the stop posi-
tion. Make sure the dipstick is inserted all the way to
the stop.
NOTE: The illustration shows the front view of the com-
pressor with the dust cover removed.
RCPH10TLB015BAL 4
7. Remove the dipstick. Count the oil level marks on the

dipstick. Use the following table to find the correct oil
level for the mounting angle of the compressor.
Compressor oil levels

Mounting angle (degrees) Dipstick reading
0 4 to 6
10 6 to 8
20 7 to 9
30 8 to 10
40 9 to 11
50 9 to 11
60 9 to 12
90 9 to 12
8. If the oil level is not correct, add or subtract oil to the

correct level as shown in the above chart.
NOTICE: Use only CNH PAG OIL.
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9. Install a new O-ring on the oil filler plug. Install the

plug and tighten to a torque of 15 - 24 N·m (11 - 18
lb ft).
RCPH10TLB676AAL 5
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Air-conditioning compressor - Disassemble - Clutch disassembly

1. See Air-conditioning compressor - Disassemble
(50.200) in this service manual for compressor re-
moval. Clean the external surfaces of the compres-
sor before doing any work on the compressor.
RCPH10TLB631AAL 1
2. Remove the mounting bolts for the clutch dust cover.
RCPH10TLB632AAL 2
3. Remove the clutch dust cover.
RCPH10TLB633AAL 3
4. Remove the retaining nut for the front plate. Use the
special spanner wrench from the service tool set to
keep the plate and shaft from turning.
RCPH10TLB634AAL 4
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5. Install the special puller from the service tool set on

the clutch front plate.
RCPH10TLB635AAL 5
6. Turn the center screw to pull the clutch front plate.
RCPH10TLB636AAL 6
7. Remove the shim(s) from the shaft.
RCPH10TLB637AAL 7
8. Remove the bearing dust cover. Be careful not to

bend the dust cover.
RCPH10TLB638AAL 8
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9. Remove the key from the rotor shaft.
RCPH10TLB639AAL 9
10. Remove the external snap ring for the bearing and
pulley assembly.
RCPH10TLB641AAL 10
11. Install the special puller internal collars into the

groove in the pulley. Install the special tool onto the
shaft. Tighten the mounting screws finger tight.
RCPH10TLB642AAL 11
12. Turn the center screw on the puller.
RCPH10TLB643AAL 12
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13. Remove the pulley and bearing assembly.
RCPH10TLB644AAL 13
14. Remove the snap ring for the clutch coil assembly.
RCPH10TLB646AAL 14
15. Disconnect the clip for the lead wire.
RCPH10TLB645AAL 15
16. Remove the clutch coil assembly.
RCPH10TLB647AAL 16
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17. Remove the internal snap ring and remove the bear-
ing from the pulley.
RCPH10TLB648AAL 17
Next operation:
Air-conditioning compressor - Assemble (50.200)
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Air-conditioning compressor - Assemble - Clutch assembly

Prior operation:
Air-conditioning compressor - Disassemble (50.200)
1. Use a ammeter (1), voltmeter and a 12 V battery (2)

to check the amperage of the clutch coil. The current
draw must be 3.6 - 4.2 A at 12 V.
A reading of more than 4.2 A indicates a short within the
coil.
No amperage reading indicates an open circuit in the coil.
Replace the clutch coil if the amperage reading is not cor-
rect.
RCPH10TLB933ABL 1
2. Install the clutch coil assembly. Align the detent ball

and socket on the coil and housing.
RCPH10TLB647AAL 2
3. Install the clip for the coil lead wire.
RCPH10TLB645AAL 3
4. Install the snap ring for the clutch coil assembly.
RCPH10TLB646AAL 4
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5. Install the bearing in the pulley and install the internal

snap ring.
RCPH10TLB648AAL 5
6. Put the pulley and bearing assembly on the front

housing hub. Install a driver on the pulley assem-
bly. Make sure that the tool is on the inner race of
the bearing.
RCPH10TLB649AAL 6
7. Support the compressor on the four mounting ears at

the compressor rear. Use a hammer to tap the pulley
assembly onto the front housing hub. As the pulley
is tapped onto the hub you can hear the difference in
sound when the pulley is fully installed. Make sure
the bearing is against the bottom of the hub.
RCPH10TLB649AAL 7
8. Install the external snap ring on the front housing

hub.
RCPH10TLB641AAL 8
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9. Install the key in the rotor shaft.
RCPH10TLB640AAL 9
10. Place the bearing dust cover in the bore. Place driver
from special tool kit over the dust cover.
RCPH10TLB650AAL 10
11. Gently tap the dust cover until it is seated.
RCPH10TLB651AAL 11
12. Install the shim(s) on the rotor shaft.
RCPH10TLB637AAL 12
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13. Install the front plate on the rotor shaft. Make sure
the keyway in the plate is aligned with the key in the
shaft. Install the driver over the shaft.
RCPH10TLB652AAL 13
14. Use a hammer to tap the plate onto the shaft. Make
sure the plate is against the clutch shims. As the
plate is tapped onto the shaft you can hear the differ-
ence in sound when the plate is fully installed.
RCPH10TLB653AAL 14
15. Install the nut on the rotor shaft. Use the spanner
wrench and a torque wrench to tighten the nut to a
torque of 15 - 20 N·m (11 - 15 lb ft).
RCPH10TLB634AAL 15
16. Use a feeler gauge to measure the gap between the

front plate and pulley assembly. The gap must be
0.41 - 0.79 mm (0.016 - 0.031 in). The gap must
be even all the way around the plate. If necessary,
lightly lift or push down on the plate to make the gap
even.
NOTE: If the gap does not meet the above specifications
remove the front plate and add or subtract clutch shims as
required.
RCPH10TLB679AAL 16
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17. Install the dust cover.
RCPH10TLB633AAL 17
18. Install and tighten the six bolts that hold the dust
cover to the compressor to 7 - 11 N·m (5 - 8 lb ft).
RCPH10TLB632AAL 18
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Air-conditioning condenser - Check - Condenser, receiver-drier,

and tubes
WARNING
Explosion hazard!
Air-conditioning refrigerant boils at -12 °C (10 °F)!
-NEVER expose any part of the air-conditioning system to a direct flame or excessive heat.
-NEVER disconnect or disassemble any part of the air-conditioning system.
Discharging refrigerant gas into the atmosphere is illegal in many countries.
W0340A
Keep the condenser fins clean and straight to make sure

there is maximum flow through the condenser and radiator
at all times. Use compressed air or a rigid brush to clean
the condenser. Also check and clean the grille screen and
radiator. Maximum air flow will prevent the engine from
getting too hot and will give the most efficient operation of
the air conditioner system.
NOTICE: Because the condenser fins bend easily, be care-
ful when you clean the condenser.
Replace the receiver-drier every other time the system is
opened for repair or service. Replace the receiver-drier
each time the system is opened under the following condi-
tions:
A. In an area where there is high moisture content
in the air.
B. If the system has been open for a long period
of time because of a leak (broken hoses, loose
connections) that has permitted air and mois-
ture to enter the system.
C. When the expansion valve is replaced (be-
cause of corrosion caused by moisture in the
system).
D. When the receiver-drier or inlet and outlet lines
feel cool to your hand when the system is op-
erating. This condition is an indication of too
much moisture in the system.
The receiver-drier must be installed with the inlet con-
nected to the hose from the condenser and the outlet
connected to the tube going to the evaporator. Always
install new O-rings when you connect the receiver-drier to
the system.
Use the two hand, two wrench method to prevent damage
to the tubes and fittings when you loosen or tighten the tube
connections.
Always replace the O-rings when you separate connec-
tions to make sure you get a good tight seal when you make
the connections again. Apply clean refrigerant oil onto the
O-rings.
47365539 08/07/2012
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RCPH10TLB669AAL 1
1. Condenser 4. Receiver-drier
2. High pressure switch 5. Hose - receiver-drier to cab
3. Hose - condenser to receiver-drier 6. Hose - compressor to condenser
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Expansion valve - Test Expansion valve testing

The following test is to be made with the expansion valve
mounted in the system. No repair, cleaning or adjustment
is recommended for the valve.
1. Remove headliner.
RCPH10TLB674AAL 1
2. Install low pressure hose to the low pressure service

port. Close both manifold valves.
3. Make sure the flow of air continues through the evap-
orator core. Start the engine and run at 1500 RPM.
Turn the blower switch to the high position, and with
the temperature control valve turned fully clockwise,
check the low pressure gauge reading.
The low pressure reading will range from 180 - 355
kPa (26 - 51 psi) when the compressor is operating.
4. Watch the low pressure gauge as ice is applied onto
the cap of the expansion valve.
The pressure must start to lower. When the pressure
reaches 28 kPa (4 psi), the low pressure indicator
will illuminate and the compressor will stop. The re-
lay must be reset after the compressor has stopped
before the system will operate again. To reset the re-
lay, turn the air conditioner to the OFF position and
then back to the desired temperature setting.
RCPH10TLB666AAL 2
5. Warm the expansion valve and watch the low pres-

sure gauge.
Within minutes, the expansion valve will open and
the pressure must rise at the low pressure gauge.
The pressure will rise to a range of 310 - 520 kPa
(45 - 75 psi).
6. If the pressure does not rise per step 5, the valve is
not operating. Replace the valve.
Evaporator and expansion valve

The refrigerant must be reclaimed from the system and all
the black insulation must be removed from the fittings and
expansion valve before the evaporator core or the expan-
sion valve are replaced.
47365539 08/07/2012
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The expansion valve must be installed with the sensor to-

ward the rear of the tractor. The port nearest to the IN
mark must point away from the evaporator core. Connect
the evaporator core fittings to the expansion valve. Install
O-rings between the evaporator core and the expansion
valve.
Connect the expansion valve to the evaporator inlet tube.
Install an O-ring between the expansion valve inlet and the
pressure hose from the receiver-drier.
Connect the suction hose to the evaporator outlet. Install
an O-ring between the fittings.
NOTE: Tighten all the connections. Use two wrenches to
prevent damage to the parts when tightening tubes and
hoses. Always replace O-rings and put clean refrigerant
oil on the O-rings.
NOTE: CNH PAG OIL must be added whenever a com-
ponent is replaced. Refer to the chart below for recom-
mended quantities.
Component Oil amount

Evaporator 44 - 50 ml (1.5 - 1.7 US fl oz)
Condenser 35 - 38 ml (1.2 - 1.3 US fl oz)
Receiver-drier 20 - 25 ml (0.7 - 0.8 US fl oz)
Hoses (normal length) 10 - 20 ml (0.3 - 0.7 US fl oz)
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Air-conditioning evaporator - Remove Evaporator Core

1. Remove the screws that hold the cover on the right-
hand center post. Then remove the cover.
2. Remove headliner.
RCPH10TLB674AAL 1
3. Remove the hose clamps (1) and disconnect the four

drain hoses (2) at the housing. Disconnect the low
pressure switch (3). Remove the bolts (4) retaining
the air ducts and remove the air ducts. Disconnect
the blower.
4. Carefully remove the four nuts that hold the housing
to the roof of the cab and lower the housing including
the blower, heater core, and air conditioner evapora-
tor to the front dash and steering wheel area.
NOTE: Be careful not to kink the air conditioner lines, as
this could cause premature failure of the hoses.
RCPH10TLB671AAL 2
5. If the insulation (1) has not been removed, remove

it now from the expansion valve and the evaporator
lines.
To test the valve see Expansion valve - Test (50.200)
in this section. Discharge the A/C system to remove the
evaporator core. See Air-conditioning evaporator - Re-
move (50.200)l.
6. Disconnect the air conditioner suction and discharge
lines (1) at the expansion valve. Remove and discard
the O-rings. Cap and plug the lines to prevent dirt
and moisture from entering the system.
7. Remove the thermostat probe for the air conditioner
control that is in the evaporator core.
8. Remove the evaporator core from the housing and
put the evaporator on a clean bench. Remove the
expansion valve from the evaporator core. It can be
necessary to use a back-up wrench to prevent dam-
age to the tubes. Remove and discard the O-rings
from between the expansion valve and the evapora-
tor core lines.
RCPH10TLB666AAL 3
Next operation:
Air-conditioning evaporator - Install (50.200)
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Air-conditioning evaporator - Install

Prior operation:
Air-conditioning evaporator - Remove (50.200)
1. Put new O-rings on the evaporator core lines. Lubri-

cate the O-rings with clean refrigerant oil.
2. Install the expansion valve. Tighten the fittings to a
torque of 25 - 34 N·m (18 - 25 lb ft). It may be nec-
essary to use a backup wrench to prevent damage
to the evaporator tubes.
3. Install the evaporator core in the housing.
4. Install the thermostat probe for the air conditioner.
NOTE: Position capillary tube so it does not interfere with
the air filter during installation and removal.
RCPH10TLB037GAL 1
1. 25 mm (1 in) 2. 150 mm (6 in) 3. 75 mm (3 in)
5. Install new O-rings on the discharge and suction lines

(1) at the expansion valve. Lubricate the O-rings with
clean refrigerant oil. Tighten the fittings to a torque
of 25 - 34 N·m (18 - 25 lb ft). It may be necessary
to use a backup wrench to prevent damage to the
evaporator tubes.
6. Connect the air conditioner discharge and suction
lines to the expansion valve. Wrap the valve and the
lines with insulation.
7. Install the evaporator core in the housing with the
heater core. Be sure the foam insulation strips are
in place to seal the plenum around the evaporator so
air is forced through the evaporator and the heater
core.
RCPH10TLB666AAL 2
47365539 08/07/2012
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8. Raise the housing into place, including the blower,

heater core and air conditioner evaporator. Fasten
with four nuts to the roof. Be sure the top insulation
strip is in place.
9. Connect the blower. Install the hose clamps (1) and
the air ducts using bolts (4). Make sure the seals on
the air ducts are in place. Connect the low pressure
switch (3). Connect the four drain hoses (2) to the
housing and tape in place to the air ducts. Connect
the blower. Make sure the seals are in place when
installing air ducts.
RCPH10TLB671AAL 3
10. Install headliner.

11. Install the cover on the center post.
RCPH10TLB673AAL 4
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Index

Air conditioning - Charging - Air conditioner system evacuation and recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Air conditioning - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Air conditioning - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Air conditioning - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air conditioning - Overview - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Air conditioning - Overview - Safety procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Air conditioning - Overview - Safety procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air conditioning - Pressure test and temperature testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Air conditioning - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Air-conditioning compressor - Adjust - Belt check and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Air-conditioning compressor - Assemble - Clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Air-conditioning compressor - Check - Oil level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Air-conditioning compressor - Disassemble - Clutch disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Air-conditioning compressor - Exploded view - Clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air-conditioning condenser - Check - Condenser, receiver-drier, and tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Air-conditioning evaporator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Air-conditioning evaporator - Remove Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Expansion valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Expansion valve - Test Expansion valve testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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PRINTED IN U.S.A.
47365539 08/07/2012
EN
SERVICE MANUAL
Electrical systems
580N
580SN WT
580SN
590SN
47365539 08/07/2012
55
Contents
Electrical systems - 55
Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.024

580N , 580SN WT , 580SN , 590SN
Harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.100

580N , 580SN WT , 580SN , 590SN
Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201

580N , 580SN WT , 580SN , 590SN
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301
580N , 580SN WT , 580SN , 590SN
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.302
580N , 580SN WT , 580SN , 590SN
External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.404

580N , 580SN WT , 580SN , 590SN
Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.408

Cab/Platform harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.510

580N , 580SN WT , 580SN , 590SN
Cab engine controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.525

580N , 580SN WT , 580SN , 590SN
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.DTC

580N , 580SN WT , 580SN , 590SN
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Transmission control system - 024
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Transmission electronic control module

Powershift - Detailed view Transmission Control Connectors, H-Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Transmission electronic control module

Powershift - Disassemble S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . . . . . . . . 5
Powershift - Assemble - S-Type (SPS Power Synchro) - Switches and sensors . . . . . . . . . . . . . . . . . . . . . 7
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Electrical systems - Transmission control system
Transmission electronic control module Powershift - Detailed view

Transmission Control Connectors, H-Type
RCPH11TLB013FAL 1
Transmission control connector locations
(1) J1 Connector (2) J2 Connector
NOTE: Remove the floor plate to gain access to the transmission control connectors, J1 and J2.
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Transmission control J1 connector

1 S1/3 and S24 solenoid common
2 S1/3 solenoid
3 S2/4 solenoid
4 4WD and HDL solenoid common
5 4WD solenoid
6 Differential lock solenoid
7 Speed sensor
8 Speed sensor
9 Temperature sensor
10 Temperature sensor
11 Pressure sensor
12 Speed, Temperature and Pressure sensor
common
RCPH11TLB027BAL 2
Transmission control J2 connector

1 Forward solenoid
2 Forward solenoid
3 Reverse solenoid
4 Reverse solenoid
5 PWM 1/3 solenoid
6 PWM 1/3 solenoid
7 PWM 2/4 solenoid
8 PWM 2/4 solenoid
RCPH11TLB028BAL 3
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Transmission electronic control module Powershift - Disassemble

S-Type (SPS Power Synchro) - Switches and sensors
1. Drain the oil from the transmission hydraulic circuit.
Remove screws, (1)Remove pipe (3) Remove gas-
kets (2)
RCPH10TLB131ACL 1
2. Remove the wiring harness (1)Remove the temper-

ature sensor and thermostat (2)
RCPH10TLB036ACL 2
3. Remove the male pressure switch (2)and washer

(1)Remove the regulating pressure valve (3)Remove
the speed sensor (4)and washer seal (5)
RCPH10TLB037ACL 3
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4. Remove the screw (1)and bracket (2). Remove the

switch gear (3)and O-rings (4).
RCPH10TLB038ACL 4
5. If necessary, remove the O-rings and the back-up

rings from the valve.
RCPH10TLB242ACL 5
NOTE: Seal rings must not be re-used

6. Remove springs (1)and pins (2)
RCPH10TLB241ACL 6
Next operation:
Transmission electronic control module Powershift - Assemble (55.024)
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Transmission electronic control module Powershift - Assemble -

S-Type (SPS Power Synchro) - Switches and sensors
Prior operation:
Transmission electronic control module Powershift - Disassemble (55.024)
1. Assemble the switch detents (1) and springs (2). Use

a magnet, if necessary.
RCPH10TLB003BAN 1
2. Remove the screw (1) and bracket (2). Remove the

switch gears (3) and O-rings (4). Torque to Power-
shift transmission - Torque (21.113)
RCPH10TLB038ACL 2
3. Assemble the switch gears as shown.
RCPH10TLB151ACL 3
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4. Use slotted sensor socket to assemble the 2nd and

4th gear switches.
RCPH10TLB157ACL 4
5. Assemble new O-rings and back-up rings on the

valve.
RCPH10TLB242ACL 5
6. Assemble the male pressure switch (1) with washer

(2). Assemble the regulating pressure valve (3).
Remove the speed sensor (4) with washer seal
(5). Torque to Powershift transmission - Torque
(21.113)
RCPH10TLB037ACL 6
7. Assemble the temperature sensor and thermostat

(1). Torque to Powershift transmission - Torque
(21.113). Assemble the wiring harness (2).
RCPH10TLB036ACL 7
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8. Assemble pipe (3)and screws (1)Replace gaskets

(2)and torque to Powershift transmission - Torque
(21.113)
RCPH10TLB131ACL 8
Next operation:
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Index

Transmission electronic control module Powershift - Assemble - S-Type (SPS Power Synchro) - Switches and sen-
sors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Transmission electronic control module Powershift - Detailed view Transmission Control Connectors, H-Type . . 3
Transmission electronic control module Powershift - Disassemble S-Type (SPS Power Synchro) - Switches and
sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Harnesses and connectors - 100
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Wire harnesses
Electrical schematic frame 01 Power Distribution/ Charging System, Power Shuttle transmission with op-
tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
580N NA Power Shuttle, 580N NA T4, 580SN NA Power Shuttle, 580SN NA T4, 580SN WT NA Power Shuttle, 580SN
WT NA T4, 590SN NA Power Shuttle, 590SN NA T4
Electrical schematic frame 01 Power Distribution/ Charging System, Power Shuttle transmission without
options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical schematic frame 01 Power Distribution/ Charging System, Powershift transmission with options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
580N NA Powershift, 580N NA T4, 580SN NA Powershift, 580SN NA T4, 580SN WT NA Powershift, 580SN WT NA
T4, 590SN NA Powershift, 590SN NA T4
Electrical schematic frame 01 Power Distribution/ Charging System, Powershift transmission without op-
tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Electrical schematic frame 02 Starting System, Power Shuttle transmission with options . . . . . . . . . . . . 20
Electrical schematic frame 02 Starting System, Power Shuttle transmission without options . . . . . . . . . 22
Electrical schematic frame 02 Starting System, Powershift transmission with options . . . . . . . . . . . . . . . 24

Electrical schematic frame 02 Starting System, Powershift transmission without options . . . . . . . . . . . . 26

Electrical schematic frame 03 Grounding, Power Shuttle transmission with options . . . . . . . . . . . . . . . . 28

Electrical schematic frame 03 Grounding, Power Shuttle transmission without options . . . . . . . . . . . . . . 30

Electrical schematic frame 03 Grounding, Powershift transmission with options . . . . . . . . . . . . . . . . . . . . 32

Electrical schematic frame 03 Grounding, Powershift transmission without options . . . . . . . . . . . . . . . . . 34

Electrical schematic frame 04 Engine Control, Power Shuttle transmission with options . . . . . . . . . . . . . 36
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Electrical schematic frame 04 Engine Control, Power Shuttle transmission without options . . . . . . . . . . 38
Electrical schematic frame 04 Engine Control, Powershift transmission with options . . . . . . . . . . . . . . . . 40

Electrical schematic frame 04 Engine Control, Powershift transmission without options . . . . . . . . . . . . . 42

Electrical schematic frame 05 Engine Control, Power Shuttle transmission with options . . . . . . . . . . . . . 44
Electrical schematic frame 05 Engine Control, Power Shuttle transmission without options . . . . . . . . . . 46
Electrical schematic frame 05 Engine Control, Powershift transmission with options . . . . . . . . . . . . . . . . 48

Electrical schematic frame 05 Engine Control, Powershift transmission without options . . . . . . . . . . . . . 50

Electrical schematic frame 06 Drives, Power Shuttle transmission with options . . . . . . . . . . . . . . . . . . . . 52

Electrical schematic frame 06 Drives, Power Shuttle transmission without options . . . . . . . . . . . . . . . . . 54

Electrical schematic frame 06 Powershift Transmission Inputs, Powershift transmission with options . 56
Electrical schematic frame 06 Powershift Transmission Inputs, Powershift transmission without options 58
Electrical schematic frame 07 Hydraulics, Power Shuttle transmission with options . . . . . . . . . . . . . . . . 60

Electrical schematic frame 07 Hydraulics, Power Shuttle transmission without options . . . . . . . . . . . . . . 62

Electrical schematic frame 07 Hydraulics, Powershift transmission with options . . . . . . . . . . . . . . . . . . . . 64

Electrical schematic frame 07 Hydraulics, Powershift transmission without options . . . . . . . . . . . . . . . . . 66

Electrical schematic frame 08 Pilot Controls, Power Shuttle transmission with options . . . . . . . . . . . . . . 68
Electrical schematic frame 08 Pilot Controls, Power Shuttle transmission without options . . . . . . . . . . . 70
Electrical schematic frame 08 Pilot Controls, Powershift transmission with options . . . . . . . . . . . . . . . . . 72

Electrical schematic frame 08 Pilot Controls, Powershift transmission without options . . . . . . . . . . . . . . 74

Electrical schematic frame 09 Front Exterior Lights, Power Shuttle transmission with options . . . . . . . . 76
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Electrical schematic frame 09 Front Exterior Lights, Power Shuttle transmission without options . . . . . 78
Electrical schematic frame 09 Front Exterior Lights, Powershift transmission with options . . . . . . . . . . . 80
Electrical schematic frame 09 Front Exterior Lights, Powershift transmission without options . . . . . . . . 82
Electrical schematic frame 10 Interior Lighting, Power Shuttle transmission with options . . . . . . . . . . . . 84
Electrical schematic frame 10 Interior Lighting, Power Shuttle transmission without options . . . . . . . . . 86
Electrical schematic frame 10 Interior Lighting, Powershift transmission with options . . . . . . . . . . . . . . . 88

Electrical schematic frame 10 Interior Lighting, Powershift transmission without options . . . . . . . . . . . . 90

Electrical schematic frame 11 Wipers and Washers, Power Shuttle transmission with options . . . . . . . 92
Electrical schematic frame 11 Wipers and Washers, Power Shuttle transmission without options . . . . . 94
Electrical schematic frame 11 Windshield Wipers, Powershift transmission with options . . . . . . . . . . . . . 96

Electrical schematic frame 11 Windshield Wipers, Powershift transmission without options . . . . . . . . . . 98

Electrical schematic frame 12 Instrument Cluster, Power Shuttle transmission with options . . . . . . . . . 100
Electrical schematic frame 12 Instrument Cluster, Power Shuttle transmission without options . . . . . . 102
Electrical schematic frame 12 Instrument Cluster, Powershift transmission with options . . . . . . . . . . . . 104
Electrical schematic frame 12 Instrument Cluster, Powershift transmission without options . . . . . . . . . 106
Electrical schematic frame 13 Power Points, Power Shuttle transmission with options . . . . . . . . . . . . . 108
Electrical schematic frame 13 Power Points, Power Shuttle transmission without options . . . . . . . . . . 110
Electrical schematic frame 13 Power Points, Powershift transmission with options . . . . . . . . . . . . . . . . 112
Electrical schematic frame 13 Power Points, Powershift transmission without options . . . . . . . . . . . . . 114
Electrical schematic frame 14 SAHR Park Brake, Power Shuttle transmission with options . . . . . . . . . 116
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Electrical schematic frame 14 SAHR Park Brake, Power Shuttle transmission without options . . . . . . 118
Electrical schematic frame 14 SAHR Park Brake, Powershift transmission with options . . . . . . . . . . . . 120
Electrical schematic frame 14 SAHR Park Brake, Powershift transmission without options . . . . . . . . . 122
Electrical schematic frame 15 HVAC, Power Shuttle transmission with options . . . . . . . . . . . . . . . . . . . 124
Electrical schematic frame 15 HVAC, Power Shuttle transmission without options . . . . . . . . . . . . . . . . . 126
Electrical schematic frame 15 HVAC, Powershift transmission with options . . . . . . . . . . . . . . . . . . . . . . . 128

Electrical schematic frame 15 HVAC, Powershift transmission without options . . . . . . . . . . . . . . . . . . . . 130

Electrical schematic frame 16 Radio, Power Shuttle transmission with options . . . . . . . . . . . . . . . . . . . . 132
Electrical schematic frame 16 Radio, Power Shuttle transmission without options . . . . . . . . . . . . . . . . . 134
Electrical schematic frame 16 Radio, Powershift transmission with options . . . . . . . . . . . . . . . . . . . . . . . 136

Electrical schematic frame 16 Radio, Powershift transmission without options . . . . . . . . . . . . . . . . . . . . 138

Electrical schematic frame 17 Rear Lights Exterior, Power Shuttle transmission with options . . . . . . . 140
Electrical schematic frame 17 Rear Lights Exterior, Power Shuttle transmission without options . . . . 142
Electrical schematic frame 17 Rear Exterior Lights, Powershift transmission with options . . . . . . . . . . 144
Electrical schematic frame 17 Rear Lights Exterior, Powershift transmission without options . . . . . . . . 146
Electrical schematic frame 18 Options, Power Shuttle transmission with options . . . . . . . . . . . . . . . . . . 148
Electrical schematic frame 18 Options, Power Shuttle transmission without options . . . . . . . . . . . . . . . 150
Electrical schematic frame 18 Options, Powershift Transmission with options . . . . . . . . . . . . . . . . . . . . 152

Electrical schematic frame 18 Options, Powershift transmission without options . . . . . . . . . . . . . . . . . . 154

Electrical schematic frame 19 Horn, Power Shuttle transmission with options . . . . . . . . . . . . . . . . . . . . 156
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Electrical schematic frame 19 Horn, Power Shuttle transmission without options . . . . . . . . . . . . . . . . . . 158
Electrical schematic frame 19 Horn, Powershift transmission with options . . . . . . . . . . . . . . . . . . . . . . . . 160

Electrical schematic frame 19 Horn, Powershift transmission without options . . . . . . . . . . . . . . . . . . . . . 162

Electrical schematic frame 20 Comfort Steer/ Ride Control, Power Shuttle transmission with options 164
Electrical schematic frame 20 Comfort Steer/ Ride Control, Power Shuttle transmission without options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Electrical schematic frame 20 Comfort Steer/ Ride Control, Powershift transmission with options . . . 168
Electrical schematic frame 20 Comfort Steer/ Ride Control, Powershift transmission without options 170
Electrical schematic frame 21 Hydraulic Options Powerlift, Power Shuttle transmission with options . 172
Electrical schematic frame 21 Hydraulic Options Powerlift, Power Shuttle transmission without options 174
Electrical schematic frame 21 Canopy Exterior Lights, Powershift transmission with options . . . . . . . . 176
Electrical schematic frame 21 Canopy Exterior Lights, Powershift transmission without options . . . . . 178
Electrical schematic frame 22 Pilot Controls Inputs, Power Shuttle transmission with options . . . . . . . 180
Electrical schematic frame 22 Pilot Control Inputs, Power Shuttle transmission without options . . . . . 182
Electrical schematic frame 22 Powershift Transmission Jumper Harness, Powershift transmission with op-
tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Electrical schematic frame 22 Powershift Transmission Jumper Harness, Powershift transmission without
options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Electrical schematic frame 23 Combo/ Aux/ Uni Hydraulics, Power Shuttle transmission with options 188
Electrical schematic frame 23 Combo/ Aux/ Uni Hydraulics, Power Shuttle transmission without options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Electrical schematic frame 23 TRAX Powershift Controller, Powershift transmission with options . . . . 192
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Electrical schematic frame 23 TRAX Powershift Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Electrical schematic frame 24 Canopy Exterior Lights, Power Shuttle transmission with options . . . . . 196
Electrical schematic frame 24 Canopy Exterior Lights, Power Shuttle transmission without options . . 198
Electrical schematic frame 24 Hydraulic PowerLift, Powershift transmissions with options . . . . . . . . . . 200
Electrical schematic frame 24 Hydraulic PowerLift, Powershift transmission without options . . . . . . . . 202
Electrical schematic frame 25 Can Bus/ Diagnostics, Power Shuttle transmission with options . . . . . . 204
Electrical schematic frame 25 Can Bus/ Diagnostics, Power Shuttle transmission without options . . . 206
Electrical schematic frame 25 Combo Hydraulics, Powershift transmission with options . . . . . . . . . . . . 208
Electrical schematic frame 25 Combo Hydraulics, Powershift transmission without options . . . . . . . . . 210
Electrical schematic frame 26 Telematics, Power Shuttle transmission with options . . . . . . . . . . . . . . . 212
Electrical schematic frame 26 Telematics, Power Shuttle transmission without options . . . . . . . . . . . . . 214
Electrical schematic frame 26 Pilot Control Inputs, Powershift transmission with options . . . . . . . . . . . 216
Electrical schematic frame 26 Pilot Control Inputs, Powershift transmission without options . . . . . . . . 218
Electrical schematic frame 27 2WD Ride Control Jumper, Power Shuttle transmission with options . . 220
Electrical schematic frame 27 Accessory Jumpers, Power Shuttle transmission without options . . . . . 222
Electrical schematic frame 27 Accessory Jumpers, Powershift transmission with options . . . . . . . . . . 224
Electrical schematic frame 27 Accessory Jumpers, Powershift transmission without options . . . . . . . . 226
Electrical schematic frame 28 Accessory Jumpers, Power Shuttle transmission with options . . . . . . . 228
Electrical schematic frame 28 CAN Bus/ Diagnostics, Powershift transmission with options . . . . . . . . 230
Electrical schematic frame 28 CAN Bus/ Diagnostics, Powershift transmission without options . . . . . 232
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Electrical schematic frame 29 Telematics, Powershift transmission with options . . . . . . . . . . . . . . . . . . 234
Electrical schematic frame 29 Telematics, Powershift transmission without options . . . . . . . . . . . . . . . . 236

Wire connectors
Component Diagram 00 – Connectors X-001 through X-009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
580N NA Powershift, 580N NA Power Shuttle, 580N NA T4, 580SN NA Powershift, 580SN NA Power Shuttle, 580SN
NA T4, 580SN WT NA Powershift, 580SN WT NA Power Shuttle, 580SN WT NA T4, 590SN NA Powershift, 590SN
NA Power Shuttle, 590SN NA T4
Component diagram 01 – Connectors X-010 through X-019 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250









Component diagram 11 – Connectors X-110 through X-119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327




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Electrical systems - Harnesses and connectors
Wire harnesses - Electrical schematic frame 01 Power Distribution/

Charging System, Power Shuttle transmission with options
580N NA Power Shuttle, 580N NA T4, 580SN NA Power Shuttle, 580SN NA T4, 580SN WT NA Power Shuttle, 580SN WT NA T4, 590SN NA Power
Shuttle, 590SN NA T4
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RCPH11TLB001JAL 1
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Charging System, Power Shuttle transmission without options
580N NA Power Shuttle, 580N NA T4, 580SN NA Power Shuttle, 580SN NA T4, 580SN WT NA Power Shuttle, 580SN WT NA T4, 590SN NA Power Shuttle,
590SN NA T4
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RCPH11TLB029JAL 1
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Charging System, Powershift transmission with options
580N NA Powershift, 580N NA T4, 580SN NA Powershift, 580SN NA T4, 580SN WT NA Powershift, 580SN WT NA T4, 590SN NA Powershift, 590SN NA T4
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RCPH11TLB056JAL 1
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Charging System, Powershift transmission without options
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RCPH11TLB085JAL 1
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Wire harnesses - Electrical schematic frame 02 Starting System, Power

Shuttle transmission with options
590SN NA T4
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RCPH11TLB002JAL 1
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Wire harnesses - Electrical schematic frame 02 Starting System, Power

Shuttle transmission without options
590SN NA T4
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RCPH11TLB030JAL 1
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Wire harnesses - Electrical schematic frame 02 Starting System,

Powershift transmission with options
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RCPH11TLB057JAL 1
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Wire harnesses - Electrical schematic frame 02 Starting System,

Powershift transmission without options
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RCPH11TLB086JAL 1
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Wire harnesses - Electrical schematic frame 03 Grounding, Power

590SN NA T4
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RCPH11TLB003JAL 1
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Wire harnesses - Electrical schematic frame 03 Grounding, Power

590SN NA T4
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RCPH11TLB031JAL 1
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Wire harnesses - Electrical schematic frame 03 Grounding, Powershift

transmission with options
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RCPH11TLB058JAL 1
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Wire harnesses - Electrical schematic frame 03 Grounding, Powershift

transmission without options
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RCPH11TLB087JAL 1
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Wire harnesses - Electrical schematic frame 04 Engine Control, Power

590SN NA T4
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RCPH11TLB114JAL 1
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590SN NA T4
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RCPH11TLB115JAL 1
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Wire harnesses - Electrical schematic frame 04 Engine Control,

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RCPH11TLB116JAL 1
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RCPH11TLB117JAL 1
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590SN NA T4
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RCPH11TLB005JAL 1
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590SN NA T4
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RCPH11TLB033JAL 1
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RCPH11TLB060JAL 1
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RCPH11TLB089JAL 1
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Wire harnesses - Electrical schematic frame 06 Drives, Power Shuttle

590SN NA T4
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RCPH11TLB006JAL 1
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Wire harnesses - Electrical schematic frame 06 Drives, Power Shuttle

590SN NA T4
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RCPH11TLB034JAL 1
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Wire harnesses - Electrical schematic frame 06 Powershift Transmission

Inputs, Powershift transmission with options
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RCPH11TLB061JAL 1
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Inputs, Powershift transmission without options
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RCPH11TLB090JAL 1
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Wire harnesses - Electrical schematic frame 07 Hydraulics, Power

590SN NA T4
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RCPH11TLB007JAL 1
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Wire harnesses - Electrical schematic frame 07 Hydraulics, Power

590SN NA T4
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RCPH11TLB035JAL 1
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Wire harnesses - Electrical schematic frame 07 Hydraulics, Powershift

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RCPH11TLB062JAL 1
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Wire harnesses - Electrical schematic frame 07 Hydraulics, Powershift

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RCPH11TLB091JAL 1
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Wire harnesses - Electrical schematic frame 08 Pilot Controls, Power

590SN NA T4
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RCPH11TLB008JAL 1
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Wire harnesses - Electrical schematic frame 08 Pilot Controls, Power

590SN NA T4
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RCPH11TLB036JAL 1
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Wire harnesses - Electrical schematic frame 08 Pilot Controls,

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RCPH11TLB063JAL 1
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Wire harnesses - Electrical schematic frame 08 Pilot Controls,

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RCPH11TLB092JAL 1
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Wire harnesses - Electrical schematic frame 09 Front Exterior Lights,

Power Shuttle transmission with options
590SN NA T4
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RCPH11TLB009JAL 1
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Power Shuttle transmission without options
590SN NA T4
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RCPH11TLB037JAL 1
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RCPH11TLB064JAL 1
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RCPH11TLB093JAL 1
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Wire harnesses - Electrical schematic frame 10 Interior Lighting, Power

590SN NA T4
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RCPH11TLB010JAL 1
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Wire harnesses - Electrical schematic frame 10 Interior Lighting, Power

590SN NA T4
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RCPH11TLB038JAL 1
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Wire harnesses - Electrical schematic frame 10 Interior Lighting,

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RCPH11TLB065JAL 1
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Wire harnesses - Electrical schematic frame 10 Interior Lighting,

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RCPH11TLB094JAL 1
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Wire harnesses - Electrical schematic frame 11 Wipers and Washers,

590SN NA T4
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RCPH11TLB011JAL 1
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Wire harnesses - Electrical schematic frame 11 Wipers and Washers,

590SN NA T4
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RCPH11TLB039JAL 1
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Wire harnesses - Electrical schematic frame 11 Windshield Wipers,

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RCPH11TLB066JAL 1
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Wire harnesses - Electrical schematic frame 11 Windshield Wipers,

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RCPH11TLB095JAL 1
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Wire harnesses - Electrical schematic frame 12 Instrument Cluster,

590SN NA T4
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RCPH11TLB012JAL 1
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590SN NA T4
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RCPH11TLB040JAL 1
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RCPH11TLB067JAL 1
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RCPH11TLB096JAL 1
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Wire harnesses - Electrical schematic frame 13 Power Points, Power

590SN NA T4
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RCPH11TLB013JAL 1
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Wire harnesses - Electrical schematic frame 13 Power Points, Power

590SN NA T4
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RCPH11TLB041JAL 1
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Wire harnesses - Electrical schematic frame 13 Power Points, Powershift

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RCPH11TLB068JAL 1
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Wire harnesses - Electrical schematic frame 13 Power Points, Powershift

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RCPH11TLB097JAL 1
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Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Power

590SN NA T4
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RCPH11TLB014JAL 1
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Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Power

590SN NA T4
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RCPH11TLB042JAL 1
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Wire harnesses - Electrical schematic frame 14 SAHR Park Brake,

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RCPH11TLB069JAL 1
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Wire harnesses - Electrical schematic frame 14 SAHR Park Brake,

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RCPH11TLB098JAL 1
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Wire harnesses - Electrical schematic frame 15 HVAC, Power Shuttle

590SN NA T4
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RCPH11TLB015JAL 1
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Wire harnesses - Electrical schematic frame 15 HVAC, Power Shuttle

590SN NA T4
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RCPH11TLB043JAL 1
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Wire harnesses - Electrical schematic frame 15 HVAC, Powershift

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RCPH11TLB070JAL 1
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Wire harnesses - Electrical schematic frame 15 HVAC, Powershift

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RCPH11TLB099JAL 1
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Wire harnesses - Electrical schematic frame 16 Radio, Power Shuttle

590SN NA T4
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RCPH11TLB016JAL 1
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Wire harnesses - Electrical schematic frame 16 Radio, Power Shuttle

590SN NA T4
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RCPH11TLB044JAL 1
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Wire harnesses - Electrical schematic frame 16 Radio, Powershift

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RCPH11TLB071JAL 1
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Wire harnesses - Electrical schematic frame 16 Radio, Powershift

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RCPH11TLB100JAL 1
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Wire harnesses - Electrical schematic frame 17 Rear Lights Exterior,

590SN NA T4
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RCPH11TLB017JAL 1
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590SN NA T4
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RCPH11TLB045JAL 1
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Wire harnesses - Electrical schematic frame 17 Rear Exterior Lights,

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RCPH11TLB072JAL 1
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RCPH11TLB101JAL 1
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Wire harnesses - Electrical schematic frame 18 Options, Power Shuttle

590SN NA T4
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RCPH11TLB018JAL 1
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Wire harnesses - Electrical schematic frame 18 Options, Power Shuttle

590SN NA T4
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RCPH11TLB046JAL 1
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Wire harnesses - Electrical schematic frame 18 Options, Powershift

Transmission with options
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RCPH11TLB073JAL 1
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Wire harnesses - Electrical schematic frame 18 Options, Powershift

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RCPH11TLB102JAL 1
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Wire harnesses - Electrical schematic frame 19 Horn, Power Shuttle

590SN NA T4
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RCPH11TLB019JAL 1
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Wire harnesses - Electrical schematic frame 19 Horn, Power Shuttle

590SN NA T4
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RCPH11TLB047JAL 1
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Wire harnesses - Electrical schematic frame 19 Horn, Powershift

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RCPH11TLB074JAL 1
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Wire harnesses - Electrical schematic frame 19 Horn, Powershift

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RCPH11TLB103JAL 1
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Wire harnesses - Electrical schematic frame 20 Comfort Steer/ Ride

Control, Power Shuttle transmission with options
590SN NA T4
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RCPH11TLB020JAL 1
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Control, Power Shuttle transmission without options
590SN NA T4
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RCPH11TLB048JAL 1
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Control, Powershift transmission with options
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RCPH11TLB075JAL 1
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Control, Powershift transmission without options
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RCPH11TLB104JAL 1
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Wire harnesses - Electrical schematic frame 21 Hydraulic Options

Powerlift, Power Shuttle transmission with options
590SN NA T4
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RCPH11TLB021JAL 1
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Wire harnesses - Electrical schematic frame 21 Hydraulic Options

Powerlift, Power Shuttle transmission without options
590SN NA T4
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RCPH11TLB049JAL 1
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Wire harnesses - Electrical schematic frame 21 Canopy Exterior Lights,

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RCPH11TLB076JAL 1
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RCPH11TLB105JAL 1
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Wire harnesses - Electrical schematic frame 22 Pilot Controls Inputs,

590SN NA T4
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RCPH11TLB022JAL 1
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Wire harnesses - Electrical schematic frame 22 Pilot Control Inputs,

590SN NA T4
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RCPH11TLB050JAL 1
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Jumper Harness, Powershift transmission with options
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RCPH11TLB077JAL 1
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Jumper Harness, Powershift transmission without options
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RCPH11TLB106JAL 1
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Wire harnesses - Electrical schematic frame 23 Combo/ Aux/ Uni

Hydraulics, Power Shuttle transmission with options
590SN NA T4
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RCPH11TLB023JAL 1
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Wire harnesses - Electrical schematic frame 23 Combo/ Aux/ Uni

Hydraulics, Power Shuttle transmission without options
590SN NA T4
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RCPH11TLB051JAL 1
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Wire harnesses - Electrical schematic frame 23 TRAX Powershift

Controller, Powershift transmission with options
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RCPH11TLB078JAL 1
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Wire harnesses - Electrical schematic frame 23 TRAX Powershift

Controller
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RCPH11TLB107JAL 1
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590SN NA T4
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RCPH11TLB024JAL 1
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590SN NA T4
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RCPH11TLB052JAL 1
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Wire harnesses - Electrical schematic frame 24 Hydraulic PowerLift,

Powershift transmissions with options
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RCPH11TLB079JAL 1
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Wire harnesses - Electrical schematic frame 24 Hydraulic PowerLift,

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RCPH11TLB108JAL 1
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Wire harnesses - Electrical schematic frame 25 Can Bus/ Diagnostics,

590SN NA T4
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RCPH11TLB025JAL 1
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Wire harnesses - Electrical schematic frame 25 Can Bus/ Diagnostics,

590SN NA T4
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RCPH11TLB053JAL 1
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Wire harnesses - Electrical schematic frame 25 Combo Hydraulics,

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RCPH11TLB080JAL 1
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Wire harnesses - Electrical schematic frame 25 Combo Hydraulics,

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RCPH11TLB109JAL 1
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Wire harnesses - Electrical schematic frame 26 Telematics, Power

590SN NA T4
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RCPH11TLB026JAL 1
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Wire harnesses - Electrical schematic frame 26 Telematics, Power

590SN NA T4
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RCPH11TLB054JAL 1
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RCPH11TLB081JAL 1
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RCPH11TLB110JAL 1
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Wire harnesses - Electrical schematic frame 27 2WD Ride Control

Jumper, Power Shuttle transmission with options
590SN NA T4
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RCPH11TLB027JAL 1
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Wire harnesses - Electrical schematic frame 27 Accessory Jumpers,

590SN NA T4
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RCPH11TLB119JAL 1
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RCPH11TLB120JAL 1
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RCPH11TLB121JAL 1
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590SN NA T4
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RCPH11TLB118JAL 1
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Wire harnesses - Electrical schematic frame 28 CAN Bus/ Diagnostics,

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RCPH11TLB083JAL 1
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Wire harnesses - Electrical schematic frame 28 CAN Bus/ Diagnostics,

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RCPH11TLB112JAL 1
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Wire harnesses - Electrical schematic frame 29 Telematics, Powershift

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RCPH11TLB084JAL 1
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Wire harnesses - Electrical schematic frame 29 Telematics, Powershift

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RCPH11TLB113JAL 1
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Wire connectors - Component Diagram 00 – Connectors X-001

through X-009
580N NA Powershift, 580N NA Power Shuttle, 580N NA T4, 580SN NA Powershift, 580SN NA Power Shuttle, 580SN NA T4, 580SN WT NA Powershift,
580SN WT NA Power Shuttle, 580SN WT NA T4, 590SN NA Powershift, 590SN NA Power Shuttle, 590SN NA T4
CONNECTOR X-001 - X-001

PIN WIRE NUMBER CIRCUIT REFERENCE
NUMBER
1 21B4 (WH) CRANK OUTPUT
2 1502 (OR) IGNITION
3 0739 (WH) HAMMER VALVE POWER
4 - -
5 - -
6 AP11 (OR) PT SPEED SENS KEY-ON
7 64B6 (WH) HORN OUTPUT
8 36H1 (BL) HYDRUALIC FILTER RESTRICTION SWITCH
9 36F1 (YE) FUEL LEVEL SENDER
10 0714 (WH) HEAVY LIFT OUTPUT
11 2112 (YE) RIDE CONTROL RELAY
12 073A (WH) AUX FORWARD OUTPUT
13 - -
14 0725 (BL) COMBO HYRAULICS SIGNAL
15 0736 (YE) AUX FORWARD OR HAMMER VALVE OUTPUT
16 4031 (WH) PARK BRAKE SOLENOID OUTPUT
17 1212 (BL) ONE-TOUCH DECEL SIGNAL
18 4021 (BL) PARK BRAKE PRESSURE SIGNAL
19 5023 (WH) LOADER QUICK COUPLER RETRACT
20 5041 (WH) B'HOE QUICK COUPLER RETRACT
21 AP74 (WH) TORQUE CONTROL OUTPUT
22 3801 (BL) AIR FILTER RESTRICTION SWITCH
23 AP63 (OR) RIDE CONTROL RELAY
AP63 (YE) RIDE CONTROL RELAY
24 - -
25 AP44 (OR) PILOT CONTROLS KEY-ON
26 - -
27 0902 (OR) COMFORT STEER KEY-ON
28 5017 (WH) QUICK COUPLER LOAD SENSE OUTPUT
29 7024 (YE) COMFORT STEER
9402 (YE) BRAKE PRESSURE SWITCH SIGNAL
30 0977 (WH) COMFORT STEER OUTPUT
7015 (WH) COMFORT STEER
31 4012 (WH) RIDE CONTROL SOLENOID OUTPUT
32 19EA (OR) TRANSMISSION KEY-ON POWER
25E2 (WH) 4WD
33 25B8 (LB) REVERSE SIGNAL
25S2 (WH) DIFF LOCK SIGNAL
34 G149 (BK) COMBO HYD. SWITCH GROUND
35 64A5 (RD) HORN B+
36 6001 (BR) A/C HIGH PRESSURE SWITCH
37 5302 (OR) RETURN TO DIG
38 2020 (YE) PT SPEED SENS SIGNAL
39 - -
40 2603 (LB) FORWARD OUTPUT
41 - -
42 2703 (LB) REVERSE OUTPUT
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NUMBER
43 - -
44 3401 (YE) ALTERNATOR CHARGING SIGNAL
45 32T1 (YE) TRANSMISSION TEMPERATURE SENDER SIGNAL
46 60A1 (BR) A/C HIGH PRESSURE SWITCH FAULT
47 31S1 (YE) TACHOMETER
• Wire harnesses - Electrical schematic frame 01 Power Distribution/ Charging System, Power Shuttle
transmission with options (55.100)
• Wire harnesses - Electrical schematic frame 06 Drives, Power Shuttle transmission with options
(55.100)
• Wire harnesses - Electrical schematic frame 07 Hydraulics, Power Shuttle transmission with options
(55.100)
• Wire harnesses - Electrical schematic frame 12 Instrument Cluster, Power Shuttle transmission with
options (55.100)
• Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Power Shuttle transmission with
options (55.100)
• Wire harnesses - Electrical schematic frame 15 HVAC, Power Shuttle transmission with options
(55.100)
• Wire harnesses - Electrical schematic frame 19 Horn, Power Shuttle transmission with options
(55.100)
• Wire harnesses - Electrical schematic frame 20 Comfort Steer/ Ride Control, Power Shuttle trans-
mission with options (55.100)
• Wire harnesses - Electrical schematic frame 21 Hydraulic Options Powerlift, Power Shuttle trans-
• Wire harnesses - Electrical schematic frame 22 Pilot Controls Inputs, Power Shuttle transmission
with options (55.100)
• Wire harnesses - Electrical schematic frame 23 Combo/ Aux/ Uni Hydraulics, Power Shuttle trans-
• Wire harnesses - Electrical schematic frame 25 Can Bus/ Diagnostics, Power Shuttle transmission
47365539 08/07/2012
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transmission without options (55.100)
• Wire harnesses - Electrical schematic frame 02 Starting System, Power Shuttle transmission without
options (55.100)
• Wire harnesses - Electrical schematic frame 06 Drives, Power Shuttle transmission without options
(55.100)
• Wire harnesses - Electrical schematic frame 07 Hydraulics, Power Shuttle transmission without op-
tions (55.100)
• Wire harnesses - Electrical schematic frame 12 Instrument Cluster, Power Shuttle transmission with-
out options (55.100)
• Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Power Shuttle transmission with-
• Wire harnesses - Electrical schematic frame 19 Horn, Power Shuttle transmission without options
(55.100)
mission without options (55.100)
without options (55.100)
• Wire harnesses - Electrical schematic frame 01 Power Distribution/ Charging System, Powershift
• Wire harnesses - Electrical schematic frame 02 Starting System, Powershift transmission with op-
tions (55.100)
• Wire harnesses - Electrical schematic frame 06 Powershift Transmission Inputs, Powershift trans-
• Wire harnesses - Electrical schematic frame 07 Hydraulics, Powershift transmission with options
(55.100)
• Wire harnesses - Electrical schematic frame 12 Instrument Cluster, Powershift transmission with
options (55.100)
• Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Powershift transmission with op-
tions (55.100)
• Wire harnesses - Electrical schematic frame 15 HVAC, Powershift transmission with options (55.100)
• Wire harnesses - Electrical schematic frame 19 Horn, Powershift transmission with options (55.100)
• Wire harnesses - Electrical schematic frame 20 Comfort Steer/ Ride Control, Powershift transmis-
sion with options (55.100)
• Wire harnesses - Electrical schematic frame 24 Hydraulic PowerLift, Powershift transmissions with
options (55.100)
• Wire harnesses - Electrical schematic frame 25 Combo Hydraulics, Powershift transmission with
options (55.100)
• Wire harnesses - Electrical schematic frame 26 Pilot Control Inputs, Powershift transmission with
options (55.100)
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• Wire harnesses - Electrical schematic frame 02 Starting System, Powershift transmission without
options (55.100)
• Wire harnesses - Electrical schematic frame 07 Hydraulics, Powershift transmission without options
(55.100)
• Wire harnesses - Electrical schematic frame 12 Instrument Cluster, Powershift transmission without
options (55.100)
• Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Powershift transmission without
options (55.100)
• Wire harnesses - Electrical schematic frame 19 Horn, Powershift transmission without options
(55.100)
sion without options (55.100)
• Wire harnesses - Electrical schematic frame 24 Hydraulic PowerLift, Powershift transmission with-
• Wire harnesses - Electrical schematic frame 25 Combo Hydraulics, Powershift transmission without
options (55.100)
• Wire harnesses - Electrical schematic frame 26 Pilot Control Inputs, Powershift transmission without
options (55.100)
87704526 1
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NUMBER
A 2503 (BL) TRANSMISSION LOGIC
4063 (YE) PARK BRAKE DECLUTCH
B 3215 (YE) KICKDOWN SIGNAL
C 25S1 (YE) DIFF LOCK SIGNAL
D 19E5 (OR) TRANSMISSION KEY-ON POWER
19E8 (OR) TRANSMISSION KEY-ON POWER
• Wire harnesses - Electrical schematic frame 18 Options, Power Shuttle transmission with options
(55.100)
• Wire harnesses - Electrical schematic frame 18 Options, Power Shuttle transmission without options
(55.100)
• Wire harnesses - Electrical schematic frame 18 Options, Powershift Transmission with options
(55.100)
• Wire harnesses - Electrical schematic frame 18 Options, Powershift transmission without options
(55.100)
87697724 2
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NUMBER
1 AP53 (OR) CUSTOMER KEY-ON
• Wire harnesses - Electrical schematic frame 02 Starting System, Power Shuttle transmission with
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
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NUMBER
1 P028 (RD) B+
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NUMBER
1 AP73 (OR) HEAVY LIFT KEY-ON
2 36R1 (BL) SEAT POSITION SWITCH
3 G071 (BK) SEAT POSITION SWITCH GROUND
4 AP75 (WH) TORQUE CONTROL KEY-ON
options (55.100)
options (55.100)
options (55.100)
options (55.100)
87695564 3
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NUMBER
1 5709 (OR) COUPLERS/EH CLAM/BOOM LOCK/RADIO KEY-ON
(55.100)
tions (55.100)
(55.100)
(55.100)
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NUMBER
B 19E6 (OR) TRANSMISSION LOGIC
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
87692855 4
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NUMBER
A G076 (BK) DIAGNOSTIC PORT GROUND
B 1021 (RD) DIAGNOSTIC B+
C E246 (YE)
D E256 (GN)
E E892 (YE) K LINE
F - -
G - -
H - -
J - -
• Wire harnesses - Electrical schematic frame 28 CAN Bus/ Diagnostics, Powershift transmission with
options (55.100)
• Wire harnesses - Electrical schematic frame 28 CAN Bus/ Diagnostics, Powershift transmission with-
87736919 5
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Wire connectors - Component diagram 01 – Connectors X-010

through X-019

NUMBER
1 4601 (VT) HAZARD LIGHT SWITCH
2 AP27 (OR) HAZARDS KEY-ON
3 47R1 (VT) RIGHT TURN SIGNAL INDICATOR
4 G100 (BK) FLASHER RELAY GROUND
5 45L9 (VT) LEFT INDICATOR LIGHT
6 47L1 (VT) LEFT TURN SIGNAL INDICATOR
7 45R9 (VT) RIGHT INDICATOR LIGHT
• Wire harnesses - Electrical schematic frame 09 Front Exterior Lights, Power Shuttle transmission
• Wire harnesses - Electrical schematic frame 09 Front Exterior Lights, Powershift transmission with
options (55.100)
• Wire harnesses - Electrical schematic frame 09 Front Exterior Lights, Powershift transmission with-
47365539 08/07/2012
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NUMBER
1 42CA (VT) REAR WORK LIGHT
2 AP59 (OR) REAR LIGHTS KEY-ON
3 19E1 (OR) TRANSMISSION KEY-ON POWER
5 - -
6 - -
9 42C8 (VT) REAR WORK LIGHT
10 G213 (BK) REAR LIGHTS RELAY COIL GROUND
12 19N1 (RD) AIR SUSPENSION SEAT B+
13 - -
14 - -
16 P016 (RD) B+
18 - -
19 41FB (VT) FRONT DRIVING LIGHT
20 P022 (RD) B+
21 AP06 (OR) COUPLERS/EH CLAM/ BOOM LOCK/RADIO KEY-ON
22 - -
23 41R7 (VT) TAIL LIGHT
24 9302 (RD) RADIO B+
25 AP02 (OR) REAR WIPER/WASHER KEY-ON
26 - -
27 AP03 (OR) 4WD/RIDE CONTROL KEY-ON
28 P029 (RD) B+
29 63R1 (OR) REAR WIPER/WASHER KEY-ON
30 - -
31 AP38 (OR) 4WD/RIDE CONTROL KEY-ON
33 AP07 (OR) COMFORT STEER KEY-ON
34 8502 (BR) A/C COMPRESSOR SOLENOID POWER
36 P015 (RD) B+
40 0491 (RD) DOME LIGHT B+
41 AP04 (OR) HVAC KEY-ON
42 P014 (RD) B+
43 AP46 (OR) SIDE LIGHTS KEY-ON
44 8403 (RD) CIGARETTE LIGHTER B+
46 P032 (RD) B+
48 P017 (RD) B+
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options (55.100)
(55.100)
(55.100)
• Wire harnesses - Electrical schematic frame 10 Interior Lighting, Power Shuttle transmission with
options (55.100)
• Wire harnesses - Electrical schematic frame 11 Wipers and Washers, Power Shuttle transmission
• Wire harnesses - Electrical schematic frame 13 Power Points, Power Shuttle transmission with op-
tions (55.100)
(55.100)
• Wire harnesses - Electrical schematic frame 16 Radio, Power Shuttle transmission with options
(55.100)
• Wire harnesses - Electrical schematic frame 17 Rear Lights Exterior, Power Shuttle transmission
(55.100)
(55.100)
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options (55.100)
(55.100)
tions (55.100)
• Wire harnesses - Electrical schematic frame 10 Interior Lighting, Power Shuttle transmission without
options (55.100)
• Wire harnesses - Electrical schematic frame 13 Power Points, Power Shuttle transmission without
options (55.100)
• Wire harnesses - Electrical schematic frame 16 Radio, Power Shuttle transmission without options
(55.100)
(55.100)
(55.100)
• Wire harnesses - Electrical schematic frame 22 Pilot Control Inputs, Power Shuttle transmission
47365539 08/07/2012
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tions (55.100)
(55.100)
• Wire harnesses - Electrical schematic frame 10 Interior Lighting, Powershift transmission with op-
tions (55.100)
• Wire harnesses - Electrical schematic frame 11 Windshield Wipers, Powershift transmission with
options (55.100)
• Wire harnesses - Electrical schematic frame 13 Power Points, Powershift transmission with options
(55.100)
• Wire harnesses - Electrical schematic frame 16 Radio, Powershift transmission with options (55.100)
• Wire harnesses - Electrical schematic frame 17 Rear Exterior Lights, Powershift transmission with
options (55.100)
(55.100)
options (55.100)
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options (55.100)
(55.100)
• Wire harnesses - Electrical schematic frame 10 Interior Lighting, Powershift transmission without
options (55.100)
• Wire harnesses - Electrical schematic frame 11 Windshield Wipers, Powershift transmission without
options (55.100)
• Wire harnesses - Electrical schematic frame 13 Power Points, Powershift transmission without op-
tions (55.100)
• Wire harnesses - Electrical schematic frame 16 Radio, Powershift transmission without options
(55.100)
• Wire harnesses - Electrical schematic frame 17 Rear Lights Exterior, Powershift transmission with-
(55.100)
(55.100)
options (55.100)
84380518 1
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NUMBER
1 4043 (OR) PARK BRAKE KEY-ON
3 P013 (RD) B+
4 1019 (RD) DIAGNOSTIC B+
6 AP72 (WH) HEAVY LIFT KEY-ON
7 1P03 (RD) INSTRUMENT CLUSTER B+
9 25A2 (LB) FORWARD SIGNAL
11 P018 (RD) B+
12 3P01 (OR) INSTRUMENT CLUSTER KEY-ON
13 5203 (YE) IN GEAR SIGNAL
15 P012 (RD) B+
16 3P0X (OR) INSTRUMENT CLUSTER KEY-ON
18 7013 (WH) COMFORT STEER
19 G051 (BK) A/C RELAY COIL GROUND
21 - -
22 - -
23 60B2 (BR) A/C LOW PRESSURE SWITCH SIGNAL
24 - -
26 G084 (BK) COMFORT STEER SOLENOID GROUND
29 - -
30 - -
31 - -
32 - -
34 5045 (YE) B'HOE QUICK COUPLER RETRACT
36 P027 (RD) B+
38 G019 (BK) B'HOE QUICK COUPLER RETRACT SOLENOID DIODE CLAMP
GROUND
40 P028 (RD) B+
41 5026 (YE) LOADER QUICK COUPLER RETRACT
42 5015 (YE) QUICK COUPLER LOAD SENSE OUTPUT
45 G017 (BK) LOADER QUICK COUPLER RETRACT SOLENOID DIODE CLAMP
GROUND
46 G018 (BK) QUICK COUPLER LOAD SENSE SOLENOID DIODE CLAMP GROUND
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options (55.100)
(55.100)
(55.100)
options (55.100)
options (55.100)
(55.100)
options (55.100)
(55.100)
tions (55.100)

tions (55.100)
options (55.100)
47365539 08/07/2012
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options (55.100)
options (55.100)
84380518 2
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NUMBER
1 G079 (BK) PARK BRAKE CUTOUT RELAY COIL GROUND
2 19M5 (OR) TRANSMISSION LOGIC
3 21C2 (YE) NEUTRAL SIGNAL
4 21A7 (OR)
5 - -
6 - -
7 - -
8 - -
11 21A8 (OR) ECU START RELAY
12 G077 (BK) NEUTRAL RELAY COIL GROUND
13 21A4 (YE) CRANK SIGNAL
14 P032 (RD) B+
15 0715 (WH) HEAVY LIFT ENABLE FROM CLUSTER
17 - -
18 - -
19 - -
20 - -
22 21A7 (OR)
24 G111 (BK) HEAVY LIFT RELAY COIL GROUND
25 4053 (YE) PARK BRAKE DECLUTCH
28 AP41 (OR) RIDE CONTROL RELAY KEY ON
29 - -
30 - -
31 - -
32 - -
33 4052 (YE) PARK BRAKE LOGIC
34 G081 (BK) PARK BRAKE RELAY COIL GROUND
36 G323 (BK) RC RELAY COIL GND
41 - -
42 - -
43 - -
44 - -
46 G065 (BK) FORWARD RELAY COIL GROUND
48 G064 (BK) REVERSE RELAY COIL GROUND
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options (55.100)
(55.100)
options (55.100)
options (55.100)
(55.100)
tions (55.100)
84380518 3
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NUMBER
2 2P01 (RD) TRAX B+
3 P013 (RD) B+
6 PO18 (RD) B+
10 - -
11 P018 (RD) B+
12 3P01 (OR) INSTRUMENT CLUSTER KEY-ON
13 AP72 (WH) HEAVY LIFT KEY-ON
14 - -
15 P012 (RD) B+
17 - -
18 - -
19 G051 (BK) A/C RELAY COIL GROUND
21 - -
22 - -
23 60B2 (BR) A/C LOW PRESSURE SWITCH SIGNAL
24 - -
25 - -
26 - -
29 - -
30 - -
31 - -
32 - -
36 P027 (RD) B+
38 G019 (BK) B'HOE QUICK COUPLER RETRACT SOLENOID DIODE CLAMP
GROUND
40 P028 (RD) B+
45 G017 (BK) LOADER QUICK COUPLER RETRACT SOLENOID DIODE CLAMP
GROUND
46 G018 (BK) QUICK COUPLER LOAD SENSE SOLENOID DIODE CLAMP GROUND
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tions (55.100)
(55.100)
options (55.100)
tions (55.100)
• Wire harnesses - Electrical schematic frame 23 TRAX Powershift Controller, Powershift transmis-
options (55.100)
options (55.100)
options (55.100)
(55.100)
options (55.100)
options (55.100)
• Wire harnesses - Electrical schematic frame 23 TRAX Powershift Controller (55.100)
84380518 4
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PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME
NUMBER
1 G074 (BK) POWER RELAY 1 COIL GROUND
2 4002 (OR) ACCESSORY
3 P005 (RD) B+
5 AP01 (OR) POWER RELAY 1 KEY-ON
84471904 5
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NUMBER
3 P008 (RD) B+
84471904 6
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NUMBER
1 G079 (BK) PARK BRAKE CUTOUT RELAY
COIL GROUND
4 21A7 (OR)
6 - -
7 - -
8 - -
9 - -
12 G077 (BK) NEUTRAL RELAY COIL GROUND
14 P032 (RD) B+
15 0715 (WH) HEAVY LIFT ENABLE FROM
CLUSTER
17 - -
18 - -
19 - -
20 - -
22 21A7 (OR)
24 G111 (BK) HEAVY LIFT RELAY COIL GROUND
28 AP41 (OR) RIDE CONTROL RELAY KEY ON
29 - -
30 - -
31 - -
32 - -
34 G081 (BK) PARK BRAKE RELAY COIL
GROUND
35 4016 (WH) RIDE CONTROL SOLENOID
OUTPUT
36 G323 (BK) RC RELAY COIL GND
37 - -
38 - -
39 - -
40 - -
41 - -
42 - -
43 - -
44 - -
45 - -
46 - -
47 - -
48 - -
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tions (55.100)
tions (55.100)
options (55.100)
options (55.100)
options (55.100)
84380518 7
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through X-029

NUMBER
A1 42C7 (VT) REAR WORK LIGHT
A2 63R4 (OR) REAR WIPER/WASHER KEY-ON
A3 45RB (VT) RIGHT INDICATOR LIGHT
A4 4400 (VT) BRAKE LIGHT
A5 45LA (VT) LEFT INDICATOR LIGHT
A6 60C4 (BR) A/C COMPRESSOR OUTPUT
A7 G059 (BK) RADIO GROUND
A8 - -
B1 8602 (BR) BLOWER MOTOR HIGH
B2 8102 (TN) REAR WIPER LOW
B3 - -
B4 41R5 (VT) TAIL LIGHT
B5 4804 (VT) ROTATING BEACON
B6 0431 (VT) SIDE WORK LIGHTS
B7 63R9 (OR) REAR WIPER/WASHER KEY-ON
B8 8802 (BR) BLOWER MOTOR LOW
C1 8702 (BR) BLOWER MOTOR MEDIUM
C2 8202 (TN) REAR WIPER HIGH
C3 8902 (TN) REAR WIPER PARK
C4 5707 (OR) COUPLERS/EH CLAM/BOOM LOCK/RADIO KEY-ON
C5 9302 (RD) RADIO B+
C6 60B2 (BR) A/C LOW PRESSURE SWITCH SIGNAL
C7 0491 (RD) DOME LIGHT B+
C8 - -
options (55.100)
(55.100)
• Wire harnesses - Electrical schematic frame 16 Radio, Power Shuttle transmission with options
(55.100)
• Wire harnesses - Electrical schematic frame 24 Canopy Exterior Lights, Power Shuttle transmission
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options (55.100)
• Wire harnesses - Electrical schematic frame 16 Radio, Power Shuttle transmission without options
(55.100)
• Wire harnesses - Electrical schematic frame 24 Canopy Exterior Lights, Power Shuttle transmission
tions (55.100)
options (55.100)
• Wire harnesses - Electrical schematic frame 16 Radio, Powershift transmission with options (55.100)
options (55.100)
• Wire harnesses - Electrical schematic frame 21 Canopy Exterior Lights, Powershift transmission
options (55.100)
options (55.100)
• Wire harnesses - Electrical schematic frame 16 Radio, Powershift transmission without options
(55.100)
• Wire harnesses - Electrical schematic frame 21 Canopy Exterior Lights, Powershift transmission
87699386 1
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55.100 / 268

NUMBER
1 P018 (RD) B+
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
87693713 2
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NUMBER
1 8702 (BR) BLOWER MOTOR MEDIUM
2 8602 (BR) BLOWER MOTOR HIGH
3 8802 (BR) BLOWER MOTOR LOW
(55.100)
87713932 3
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NUMBER
1 25E1 (LB) 4WD
2 AP40 (OR) 4WD KEY-ON
3 25C2 (YE) 4WD SIGNAL
4 - -
5 - -
6 - -
7 - -
8 - -
9 G072 (BK) 4WD SWITCH LAMP SWITCH GROUND
10 - -
(55.100)
(55.100)
84159859 4
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NUMBER
1 - -
2 AP61 (OR) RIDE CONTROL KEY-ON
3 1010 (YE) RIDE CTRL SW ON SIGNAL
5 1080 (YE) RIDE CTRL SW OFF SIGNAL
6 - -
8 - -
9 G092 (BK) RIDE CONTROL SWITCH GROUND
10 - -
84159859 5
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NUMBER
1 1121 (RD) ENTER SIGNAL
3 1111 (RD) DISPLAY SIGNAL
4 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 - -
options (55.100)
options (55.100)
options (55.100)
84159859 6
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NUMBER
1 1141 (RD) DOWN SIGNAL
3 1131 (RD) UP SIGNAL
4 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 - -
options (55.100)
options (55.100)
options (55.100)
84159859 7
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NUMBER
1 - -
21C7 (YE) NEUTRAL SIGNAL
4 41R6 (VT) TAIL LIGHT
5 42FA (VT) FRONT WORK LIGHT
6 42C9 (VT) REAR WORK LIGHT
7 4409 (VT) BRAKE LIGHT
8 - -
9 0711 (YE) HEAVY LIFT INPUT TO CLUSTER
11 1111 (RD) DISPLAY SIGNAL
12 1121 (RD) ENTER SIGNAL
13 1131 (RD) UP SIGNAL
14 1141 (RD) DOWN SIGNAL
19 36R1 (BL) SEAT POSITION SWITCH
20 1202 (BL) FOOT THROTTLE IDEL VALIDATION
22 - -
23 - -
24 - -
25 - -
26 - -
options (55.100)
options (55.100)
options (55.100)
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82016219 8
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NUMBER
2 - -
3 E259 (GN)
4 E249 (YE)
5 - -
6 2601 (WH) AUDIBLE ALARM OUTPUT
7 0715 (WH) HEAVY LIFT ENABLE FROM
CLUSTER
9 - -
11 - -
12 - -
14 32T2 (YE) TRANSMISSION TEMPERATURE
SENDER SIGNAL
15 - -
16 2162 (YE) FOOT THROTTLE SIGNAL
17 2171 (YE) HAND THROTTLE SIGNAL
18 2182 (PK) FOOT THROTTLE 5V
19 2191 (PK) HAND THROTTLE 5V
20 2202 (BL) FOOT THROTTLE GROUND
21 2211 (GN) HAND THROTTLE GROUND
22 1010 (YE) RIDE CTRL SW ON SIGNAL
23 1080 (YE) RIDE CTRL SW OFF SIGNAL
25 2125 (YE)
26 G066 (BK) INSTRUMENT CLUSTER GROUND
options (55.100)
options (55.100)
options (55.100)
47365539 08/07/2012
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82028493 9
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through X-039

NUMBER
A 2601 (WH) AUDIBLE ALARM OUTPUT
B G058 (BK) AUDIBLE ALARM GROUND
options (55.100)
options (55.100)
options (55.100)
87692877 1
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55.100 / 279

NUMBER
(55.100)
(55.100)
(55.100)
84177908 2
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NUMBER
1 G063 (BK) HORN GROUND
(55.100)
(55.100)
(55.100)
84177908 3
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NUMBER
A 2191 (PK) HAND THROTTLE 5V
B 2171 (YE) HAND THROTTLE SIGNAL
C 2211 (GN) HAND THROTTLE GROUND
options (55.100)
options (55.100)
options (55.100)
84277203 4
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NUMBER
D 5018 (YE) B'HOE QUICK COUPLER EXTEND
E 5706 (OR) COUPLERS/EH CLAM/BOOM LOCK/RADIO KEY-ON
F 504A (YE) B'HOE QUICK COUPLER RETRACT
(55.100)
(55.100)
87697780 5
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NUMBER
E 504A (YE) B'HOE QUICK COUPLER RETRACT
F 5043 (YE) B'HOE QUICK COUPLER RETRACT
(55.100)
(55.100)
87697780 6
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NUMBER
1 - -
3 6502 (WH) REAR WINDSHIELD WASHER PUMP OUTPUT
4 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 - -
options (55.100)
options (55.100)
84159859 7
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NUMBER
1 6602 (TN) FRONT WIPER LOW
2 63F2 (OR) FRONT WIPER/WASHER KEY-ON
3 6702 (TN) FRONT WIPER HIGH
4 6902 (TN) FRONT WIPER PARK
5 - -
6 - -
7 - -
8 - -
9 - -
10 - -
options (55.100)
options (55.100)
84159859 8
47365539 08/07/2012
55.100 / 286

NUMBER
A 5702 (OR) COUPLERS/EH CLAM/BOOM LOCK/RADIO KEY-ON
B G179 (BK) EH CLAM GROUND
(55.100)
tions (55.100)
(55.100)
(55.100)
87693821 9
47365539 08/07/2012
55.100 / 287

through X-049

NUMBER
1 P024 (RD) B+
2 64A4 (RD) HORN B+
3 45RA (VT) RIGHT INDICATOR LIGHT
4 P026 (RD) B+
5 P021 (RD) B+
6 P030 (RD) B+
8 25B1 (YE) REVERSE SIGNAL
25B3 (LB) REVERSE SIGNAL
9 42F1 (VT) FRONT WORK LIGHT
10 41FD (VT) FRONT DRIVING LIGHT
E081 (YE) CRANK SIGNAL
5205 (YE) IN GEAR SIGNAL
25A4 (LB) FORWARD SIGNAL
15 5011 (YE) LOADER QUICK COUPLER EXTEND
24 3211 (YE) KICKDOWN SIGNAL
21C5 (YE) NEUTRAL SIGNAL
26 - -
29 1201 (BL) FOOT THROTTLE IDLE VALIDATION
30 E242 (YE) CAN 1 HIGH
31 E252 (GN) CAN 1 LOW
32 150B (OR) IGNITION
3224 (YE) GEAR COMMAND 2
35 150B (OR) IGNITION
2501 (BL) TRANSMISSION LOGIC
37 60C5 (BR) A/C COMPRESSOR OUTPUT
38 3583 (YE) AUTO SIGNAL
47365539 08/07/2012
55.100 / 288

NUMBER
39 1901 (YE) GEAR COMMAND 1
40 0972 (YE) COMFORT STEER OUTPUT
7023 (YE) COMFORT STEER
41 4803 (VT) ROTATING BEACON
43 E682 (YE) K LINE
47 41FC (VT) FRONT DRIVING LIGHT
options (55.100)
(55.100)
(55.100)
options (55.100)
(55.100)
(55.100)
47365539 08/07/2012
55.100 / 289
options (55.100)
(55.100)
(55.100)
tions (55.100)
(55.100)
options (55.100)
options (55.100)
options (55.100)
options (55.100)
options (55.100)
47365539 08/07/2012
55.100 / 290
options (55.100)
options (55.100)
options (55.100)
(55.100)
87713304 1
47365539 08/07/2012
55.100 / 291

NUMBER
4063 (YE) PARK BRAKE DECLUTCH
B 3215 (YE) KICKDOWN SIGNAL
C 25S1 (YE) DIFF LOCK SIGNAL
D 19E5 (OR) TRANSMISSION KEY-ON POWER
(55.100)
(55.100)
(55.100)
(55.100)
47365539 08/07/2012
55.100 / 292

through X-059

NUMBER
4 - -
5 - -
11 2125 (YE)
12 0732 (WH) AUX FORWARD OUTPUT
13 - -
14 0729 (BL) COMBO HYDRAULICS SIGNAL
15 0737 (YE) AUX FORWARD OF HAMMER VALVE OUTPUT
24 - -
26 - -
29 7014 (WH) COMFORT STEER
9403 (YE) BRAKE PRESSURE SWITCH SIGNAL
32 19EF (OR) TRANSMISSION KEY-ON POWER
25E1 (LB) 4WD
25S1 (YE) DIFF LOCK SIGNAL
39 - -
41 - -
43 - -
47365539 08/07/2012
55.100 / 293

NUMBER
options (55.100)
(55.100)
(55.100)
options (55.100)
options (55.100)
(55.100)
(55.100)
47365539 08/07/2012
55.100 / 294
options (55.100)
(55.100)
tions (55.100)
(55.100)
47365539 08/07/2012
55.100 / 295
tions (55.100)
(55.100)
options (55.100)
tions (55.100)
options (55.100)
options (55.100)
options (55.100)
options (55.100)
(55.100)
options (55.100)
options (55.100)
(55.100)
options (55.100)
options (55.100)
47365539 08/07/2012
55.100 / 296
84365917 1
47365539 08/07/2012
55.100 / 297

NUMBER
A 4014 (WH) RIDE CONTROL SOLENOID OUTPUT
B G091 (BK) RIDE CONTROL SOLENOID GROUND
87691549 2
47365539 08/07/2012
55.100 / 298

NUMBER
2 5301 (BL) RETURN TO DIG
(55.100)
tions (55.100)
(55.100)
(55.100)
84277193 3
47365539 08/07/2012
55.100 / 299

NUMBER
A 64A5 (RD) HORN B+
B 64B5 (WH) HORN OUTPUT
C AP44 (OR) PILOT CONTROLS KEY-ON
D G116 (BK) PILOT CONTROLS GROUND
E 1212 (BL) ONE-TOUCH DECEL SIGNAL
F G149 (BK) COMBO HYD. SWITCH GROUND
G 0725 (BL) COMBO HYRAULICS SIGNAL
H 0736 (YE) AUX FORWARD OR HAMMER VALVE OUTPUT
J 073A (WH) AUX FORWARD OUTPUT
K 0739 (WH) HAMMER VALVE POWER
• Wire harnesses - Electrical schematic frame 03 Grounding, Power Shuttle transmission with options
(55.100)
options (55.100)
(55.100)
• Wire harnesses - Electrical schematic frame 03 Grounding, Power Shuttle transmission without op-
tions (55.100)
(55.100)
• Wire harnesses - Electrical schematic frame 03 Grounding, Powershift transmission with options
(55.100)
options (55.100)
options (55.100)
options (55.100)
47365539 08/07/2012
55.100 / 300
• Wire harnesses - Electrical schematic frame 03 Grounding, Powershift transmission without options
(55.100)
options (55.100)
(55.100)
options (55.100)
options (55.100)
87698254 4
47365539 08/07/2012
55.100 / 301

NUMBER
A 25B8 (LB) REVERSE SIGNAL
2702 (LB) REVERSE OUTPUT
B G030 (BK) BACKUP ALARM GROUND
(55.100)
(55.100)
87692855 5
47365539 08/07/2012
55.100 / 302

NUMBER
A 4013 (WH) RIDE CONTROL SOLENOID OUTPUT
B G090 (BK) RIDE CONTROL ACCUMULATOR SOLENOID GROUND
87691549 6
47365539 08/07/2012
55.100 / 303

NUMBER
2 G020 (BK) PARK BRAKE SOLENOID GROUND
options (55.100)
tions (55.100)
options (55.100)
84277193 7
47365539 08/07/2012
55.100 / 304

NUMBER
A 0977 (WH) COMFORT STEER OUTPUT
B G083 (BK) COMFORT STEER SOLENOID GROUND
87693821 8
47365539 08/07/2012
55.100 / 305

NUMBER
A 5041 (WH) B'HOE QUICK COUPLER RETRACT
B G025 (BK) B'HOE QUICK COUPLER RETRACT SOLENOID GROUND
(55.100)
tions (55.100)
(55.100)
(55.100)
87693821 9
47365539 08/07/2012
55.100 / 306

through X-069

NUMBER
A 5023 (WH) LOADER QUICK COUPLER RETRACT
B G024 (BK) LOADER QUICK COUPLER RETRACT SOLENOID GROUND
(55.100)
tions (55.100)
(55.100)
(55.100)
87693821 1
47365539 08/07/2012
55.100 / 307

NUMBER
A 5017 (WH) QUICK COUPLER LOAD SENSE OUTPUT
B G023 (BK) QUICK COUPLER LOAD SENSE SOLENOID GROUND
(55.100)
tions (55.100)
(55.100)
(55.100)
87691549 2
47365539 08/07/2012
55.100 / 308

NUMBER
2 G021 (BK) FUEL SENDER GROUND
options (55.100)

options (55.100)
options (55.100)
87687244 3
47365539 08/07/2012
55.100 / 309

NUMBER
1 G022 (BK) AIR FILTER RESTRICTION SWITCH GROUND
options (55.100)
options (55.100)
options (55.100)
84177908 4
47365539 08/07/2012
55.100 / 310

NUMBER
options (55.100)
options (55.100)
options (55.100)
84177908 5
47365539 08/07/2012
55.100 / 311

through X-079

NUMBER
options (55.100)
options (55.100)
options (55.100)
47365539 08/07/2012
55.100 / 312

NUMBER
1 64A6 (RD) HORN B+
(55.100)
(55.100)
(55.100)
84364861 1
47365539 08/07/2012
55.100 / 313

NUMBER
(55.100)
(55.100)
(55.100)
84364861 2
47365539 08/07/2012
55.100 / 314

NUMBER
1 5301 (BL) RETURN TO DIG
(55.100)
tions (55.100)
(55.100)
(55.100)
84159852 3
47365539 08/07/2012
55.100 / 315

NUMBER
1 G069 (BK) RETURN TO DIG GROUND
(55.100)
tions (55.100)
(55.100)
(55.100)
84159852 4
47365539 08/07/2012
55.100 / 316

NUMBER
84277193 5
47365539 08/07/2012
55.100 / 317

NUMBER
1 25S2 (WH) DIFF LOCK SIGNAL
2 G028 (BK) DIFF LOCK SOLENOID GROUND
(55.100)
(55.100)
84277535 6
47365539 08/07/2012
55.100 / 318

NUMBER
1 25E2 (WH) 4WD
2 G029 (BK) 4WD SOLENOID GROUND
(55.100)
(55.100)
84277532 7
47365539 08/07/2012
55.100 / 319

NUMBER
2 G045 (BK) FORWARD SOLENOID GROUND
(55.100)
(55.100)
84277533 8
47365539 08/07/2012
55.100 / 320

through X-089

NUMBER
2 G044 (BK) REVERSE SOLENOID GROUND
(55.100)
(55.100)
84277534 1
47365539 08/07/2012
55.100 / 321

NUMBER
84165069 2
47365539 08/07/2012
55.100 / 322

NUMBER
A 6001 (BR) A/C HIGH PRESSURE SWITCH
B 60A1 (BR) A/C HIGH PRESSURE SWITCH FAULT
(55.100)
87692855 3
47365539 08/07/2012
55.100 / 323

through X-099

NUMBER
1 AP74 (WH) TORQUE CONTROL OUTPUT
2 G310 (BK) TORQUE CONTROL SOLENOID GROUND
options (55.100)
84426131 1
47365539 08/07/2012
55.100 / 324

NUMBER
4 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 - -
options (55.100)
tions (55.100)
options (55.100)
84159859 2
47365539 08/07/2012
55.100 / 325

NUMBER
options (55.100)
tions (55.100)
options (55.100)
87687239 3
47365539 08/07/2012
55.100 / 326

through X-119

NUMBER
1 - -
3 0431 (VT) SIDE WORK LIGHTS
4 - -
6 42CA (VT) REAR WORK LIGHT
7 - -
8 - -
9 G099 (BK) REAR LIGHTS SWITCH GROUND
10 - -
options (55.100)
84159859 1
47365539 08/07/2012
55.100 / 327

NUMBER
1 - -
2 AP37 (OR) BEACON KEY-ON
4 - -
5 - -
6 - -
7 - -
8 - -
9 G087 (BK) ROTATING BEACON SWITCH GROUND
10 - -
options (55.100)
84159859 2
47365539 08/07/2012
55.100 / 328

through X-129

NUMBER
1 P002 (RD) BATTERY CABLE FROM STARTER B+
47365539 08/07/2012
55.100 / 329

NUMBER
1 P005 (RD) B+
P006 (RD) B+
P008 (RD) B+
P009 (RD) B+
P010 (RD) B+
P027 (RD) B+
84364890 1
47365539 08/07/2012
55.100 / 330

through X-139

NUMBER
1 - -
2 AP28 (OR) HAZARDS KEY-ON
3 4601 (VT) HAZARD LIGHT SWITCH
4 - -
5 - -
6 - -
7 - -
8 - -
9 G088 (BK) HAZARD SWITCH GROUND
10 - -
options (55.100)
84159859 1
47365539 08/07/2012
55.100 / 331

NUMBER
A 6501 (WH) REAR WINDSHIELD WASHER PUMP OUTPUT
B G095 (BK) REAR WINDSHIELD WASHER PUMP GROUND
options (55.100)
options (55.100)
87693325 2
47365539 08/07/2012
55.100 / 332

NUMBER
A 6201 (WH) FRONT WINDSHIELD WASHER PUMP OUTPUT
B G096 (BK) FRONT WINDSHIELD WASHER PUMP GROUND
options (55.100)
options (55.100)
87693325 3
47365539 08/07/2012
55.100 / 333

NUMBER
1 - -
2 AP24 (OR) FRONT WORK LIGHT KEY-ON
4 - -
5 - -
6 - -
7 - -
8 - -
9 G086 (BK) FRONT WORK LIGHT SWITCH GROUND
10 - -
options (55.100)
84159859 4
47365539 08/07/2012
55.100 / 334

NUMBER
1 G089 (BK) TURN SIGNAL INDICATOR LAMPS GROUND
2 47R1 (VT) RIGHT TURN SIGNAL INDICATOR
3 47L1 (VT) LEFT TURN SIGNAL INDICATOR
options (55.100)
47365539 08/07/2012
55.100 / 335

NUMBER
L 45R8 (VT) RIGHT INDICATOR LIGHT
R 45LB (VT) LEFT INDICATOR LIGHT
56 AP30 (OR) FRONT DRIVING LIGHTS KEY-ON
31B 64A4 (RD) HORN B+
49A AP29 (OR) SIGNAL LIGHTS KEY-ON
56A 41F7 (VT) FRONT DRIVING LIGHT
(55.100)
(55.100)
options (55.100)
(55.100)
87318288 5
47365539 08/07/2012
55.100 / 336

through X-149

NUMBER
3 AP33 (OR) BRAKE LIGHTS KEY-ON
options (55.100)
47365539 08/07/2012
55.100 / 337

NUMBER
options (55.100)
47365539 08/07/2012
55.100 / 338

NUMBER
1 0963 (YE) COMFORT STEER ENABLE
3 - -
5 0953 (YE) COMFORT STEER LOGIC CIRCUIT
6 - -
7 - -
8 G085 (BK) COMFORT STEER SWITCH GROUND
9 - -
10 0975 (YE) COMFORT STEER OUTPUT
84159859 1
47365539 08/07/2012
55.100 / 339

NUMBER
1 8102 (TN) REAR WIPER LOW
3 8202 (TN) REAR WIPER HIGH
4 8902 (TN) REAR WIPER PARK
5 - -
6 - -
7 - -
8 - -
9 - -
10 - -
options (55.100)
options (55.100)
84159859 2
47365539 08/07/2012
55.100 / 340

NUMBER
1 - -
3 6201 (WH) FRONT WINDSHIELD WASHER PUMP OUTPUT
4 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 - -
options (55.100)
options (55.100)
84159859 3
47365539 08/07/2012
55.100 / 341

NUMBER
1 5011 (YE) LOADER QUICK COUPLER EXTEND
(55.100)
(55.100)
84159859 4
47365539 08/07/2012
55.100 / 342

NUMBER
1 - -
A 25B1 (YE) REVERSE SIGNAL
B 21C5 (YE) NEUTRAL SIGNAL
C 25A1 (LB) FORWARD SIGNAL
D 2104 (YE) FNR LEVER KEY ON
(55.100)
(55.100)
84165087 5
47365539 08/07/2012
55.100 / 343

NUMBER
2 P025 (RD) B+
4 P031 (RD) B+
5 - -
6 - -
7 - -
8 - -
2401 (YE) TRANSMISSION LOGIC
G005 (BK) CLUTCH RELAY COIL GROUND
18 - -
19 2103 (YE) FNR LEVER KEY ON
20 - -
22 G026 (BK) SHUTTLE INTERLOCK RELAY COIL GROUND
G084 (BK) COMFORT STEER SOLENOID GROUND
24 2501 (BL) TRANSMISSION LOGIC
G080 (BK) COMFORT STEER RELAY COIL GROUND
25 E372 (YE) CRANK ENABLE FROM ECU
29 - -
30 - -
33 G326 (BK) INTERLOCK RELAY COIL GROUND
37 - -
38 - -
41 AP21 (OR) FRONT WIPER KEY-ON
42 AP23 (OR) SIGNAL LIGHTS KEY-ON
44 AP32 (OR) DRIVING LIGHTS KEY-ON
47365539 08/07/2012
55.100 / 344

NUMBER
46 AP26 (OR) SIGNAL LIGHTS KEY-ON
48 AP30 (OR) FRONT DRIVING LIGHTS KEY-ON
options (55.100)
(55.100)
options (55.100)
(55.100)
47365539 08/07/2012
55.100 / 345
tions (55.100)
options (55.100)
options (55.100)
options (55.100)
options (55.100)
options (55.100)
84380518 6
47365539 08/07/2012
55.100 / 346

NUMBER
85 2401 (YE) TRANSMISSION LOGIC
86 2105 (YE) FNR LEVER KEY ON
87 G003 (BK) SHUTTLE INTERLOCK TIMING RELAY GROUND
(55.100)
(55.100)
84153826 7
47365539 08/07/2012
55.100 / 347

NUMBER
A 41F9 (VT) FRONT DRIVING LIGHT
B 63F6 (OR) FRONT WIPER/WASHER KEY-ON
C 45RD (VT) RIGHT INDICATOR LIGHT
D 6703 (TN) FRONT WIPER HIGH
E 6603 (TN) FRONT WIPER LOW
F 42F9 (VT) FRONT WORK LIGHT
G 6903 (TN) FRONT WIPER PARK
H 45LC (VT) LEFT INDICATOR LIGHT
J 42F6 (VT) FRONT WORK LIGHT
K 41F6 (VT) FRONT DRIVING LIGHT
L - -
M - -
options (55.100)
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
47365539 08/07/2012
55.100 / 348
84137524 8
47365539 08/07/2012
55.100 / 349

through X-159

NUMBER
1 P007 (RD) B+
2 64A3 (RD) HORN B+
3 45R5 (VT) RIGHT INDICATOR LIGHT
4 P019 (RD) B+
5 P003 (RD) B+
6 P004 (RD) B+
10 41F8 (VT) FRONT DRIVING LIGHT
25A5 (LB) FORWARD SIGNAL
26 - -
29 1202 (BL) FOOT THROTTLE IDEL VALIDATION
30 E243 (YE)
31 E253 (GN)
32 150C (OR) IGNITION
35 150C (OR) IGNITION
2506 (BL) TRANSMISSION LOGIC
47365539 08/07/2012
55.100 / 350

NUMBER
43 E892 (YE) K LINE
47 41F6 (VT) FRONT DRIVING LIGHT
options (55.100)
(55.100)
(55.100)
options (55.100)
(55.100)
(55.100)
47365539 08/07/2012
55.100 / 351
options (55.100)
(55.100)
(55.100)
tions (55.100)
(55.100)
options (55.100)
options (55.100)
options (55.100)
options (55.100)
options (55.100)
47365539 08/07/2012
55.100 / 352
options (55.100)
options (55.100)
options (55.100)
(55.100)
84365917 1
47365539 08/07/2012
55.100 / 353

NUMBER
A 2161 (YE) FOOT THROTTLE SIGNAL
B 2201 (BL) FOOT THROTTLE GROUND
C 2181 (PK) FOOT THROTTLE 5V
D - -
E 1201 (BL) FOOT THROTTLE IDLE VALIDATION
F - -
options (55.100)
options (55.100)
options (55.100)
87699184 2
47365539 08/07/2012
55.100 / 354

through X-189

NUMBER
A 8401 (RD) CIGARETTE LIGHTER B+
B G068 (BK) CIGARETTE LIGHTER GROUND
tions (55.100)
options (55.100)
(55.100)
tions (55.100)
87697531 1
47365539 08/07/2012
55.100 / 355

NUMBER
A 8402 (RD) CIGARETTE LIGHTER B+
B G070 (BK) CIGARETTE LIGHTER GROUND
tions (55.100)
options (55.100)
(55.100)
tions (55.100)
87697531 2
47365539 08/07/2012
55.100 / 356

NUMBER
A 19N1 (RD) AIR SUSPENSION SEAT B+
B G067 (BK) AIR SEAT MOTOR GROUND
(55.100)
(55.100)
(55.100)
(55.100)
87692877 3
47365539 08/07/2012
55.100 / 357

NUMBER
1 - -
2 AP51 (OR) POWER LIFT KEY-ON
3 0711 (YE) POWER LIFT INPUT TO CLUSTER
4 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 - -
options (55.100)
84159859 4
47365539 08/07/2012
55.100 / 358

through X-229

NUMBER
options (55.100)
options (55.100)
options (55.100)
87679525 1
47365539 08/07/2012
55.100 / 359

NUMBER
(55.100)
87691967 2
47365539 08/07/2012
55.100 / 360

NUMBER
(55.100)
87699700 3
47365539 08/07/2012
55.100 / 361

through X-279

NUMBER
2 0729 (BL) COMBO HYDRAULICS SIGNAL
3 - -
5 0737 (YE) AUX FORWARD OF HAMMER VALVE OUTPUT
6 0732 (WH) AUX FORWARD OUTPUT
7 - -
8 - -
9 - -
10 - -
options (55.100)
options (55.100)
84159859 1
47365539 08/07/2012
55.100 / 362

NUMBER
1 0714 (WH) POWER LIFT OUTPUT
0718 (WH) POWER LIFT OUTPUT
2 G110 (BK) POWER LIFT SOLENOID GROUND
options (55.100)
84277193 2
47365539 08/07/2012
55.100 / 363

NUMBER
1 0719 (WH)
2 G327 (BK) POWER LIFT SOLENOID GROUND
options (55.100)
84277193 3
47365539 08/07/2012
55.100 / 364

through X-309

NUMBER
1 2P01 (RD) TRAX B+
3 3053 (WH) FORWARD SOLENOID OUTPUT
4 3063 (WH) REVERSE SOLENOID OUTPUT
5 19ED (OR) TRANSMISSION KEY-ON POWER
6 3043 (WH) S2 SOLENOID OUTPUT
8 19EC (OR) TRANSMISSION KEY-ON POWER
10 - -
11 3573 (WH) DIFF LOCK SOLENOID OUTPUT
12 3073 (GY) FORWARD SOLENOID RETURN
13 3033 (GY) PWM 1/3 SOLENOID RETURN
14 - -
15 3541 (YE) GEAR SWITCH 1/2
17 0401 (BL) TRAX SIGNAL GROUND
20 - -
22 25C2 (YE) 4WD SIGNAL
24 - -
25 3301 (BL) TRANSMISSION SPEED SENSOR SIGNAL
26 - -
27 E247 (YE) CAN HIGH
28 - -
29 G101 (BK) TRAX CONTROLLER GROUND
30 - -
31 - -
32 - -
33 - -
34 19EB (OR) TRANSMISSION KEY-ON POWER
35 - -
36 - -
37 - -
39 25X3 (WH) 4WD OUTPUT
40 3083 (GY) REVERSE SOLENOID RETURN
41 3603 (GY) PWM 2/4 SOLENOID RETURN
42 - -
43 3431 (YE) TRANSMISSION TEMPERATURE SIGNAL TO TRAX
44 3441 (YE) TRANSMISSION CHARGE PRESSURE SIGNAL
45 3451 (YE) GEAR SWITCH 3/4
47365539 08/07/2012
55.100 / 365

NUMBER
48 - -
50 9403 (YE) BRAKE PRESSURE SWITCH SIGNAL
51 25S1 (YE) DIFF LOCK SIGNAL
52 - -
54 3151 (PK) TRAX 5V OUTPUT
55 E257 (GN)
56 - -
87747310 1
47365539 08/07/2012
55.100 / 366

through X-349

NUMBER
3 - -
4 - -
5 - -
6 - -
7 - -
8 G043 (BK) AUTO/MANUAL SWITCH GROUND
9 - -
84159859 1
47365539 08/07/2012
55.100 / 367

NUMBER
A1 G108 (BK) TRAX CONTROLLER POWER GROUND
A2 3053 (WH) FORWARD SOLENOID OUTPUT
A3 3063 (WH) REVERSE SOLENOID OUTPUT
A4 3013 (WH) S1 SOLENOID OUTPUT
A5 - -
A6 - -
A7 3023 (WH) S4 SOLENOID OUTPUT
A8 3541 (YE) GEAR SWITCH 1/2
B1 3151 (PK) TRAX 5V OUTPUT
B2 3073 (GY) FORWARD SOLENOID RETURN
B3 3083 (GY) REVERSE SOLENOID RETURN
B4 25X3 (WH) 4WD OUTPUT
B5 3573 (WH) DIFF LOCK SOLENOID OUTPUT
B6 19EE (OR) TRANSMISSION KEY-ON POWER
B7 3301 (BL) TRANSMISSION SPEED SENSOR SIGNAL
B8 3451 (YE) GEAR SWITCH 3/4
C1 - -
C2 3043 (WH) S2 SOLENOID OUTPUT
C3 3033 (GY) PWM 1/3 SOLENOID RETURN
C4 3593 (WH) S3 SOLENOID OUTPUT
C5 3603 (GY) PWM 2/4 SOLENOID RETURN
C6 3431 (YE) TRANSMISSION TEMPERATURE SIGNAL TO TRAX
C7 3441 (YE) TRANSMISSION CHARGE PRESSURE SIGNAL
C8 0401 (BL) TRAX SIGNAL GROUND
• Wire harnesses - Electrical schematic frame 22 Powershift Transmission Jumper Harness, Power-
shift transmission with options (55.100)
• Wire harnesses - Electrical schematic frame 22 Powershift Transmission Jumper Harness, Power-
shift transmission without options (55.100)
87714265 2
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55.100 / 368

NUMBER
A 19EA (OR) TRANSMISSION KEY-ON POWER
B 9401 (YE) BRAKE PRESSURE SWITCH SIGNAL
87692855 3
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55.100 / 369

through X-359

NUMBER
A 9401 (YE) BRAKE PRESSURE SWITCH SIGNAL
B 9402 (YE) BRAKE PRESSURE SWITCH SIGNAL
87692855 1
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55.100 / 370

through X-449

NUMBER
1 OR E05A SP-151 from ECU Relay
2 OR E05A Fuse to ECU
3 RD E054 SP-151 from ECU Relay
4 RD E054 Fuse to ECU
5 RD E055 SP-151 from ECU Relay
6 RD E055 Fuse to SP-152
• Wire harnesses - Electrical schematic frame 04 Engine Control, Power Shuttle transmission with
options (55.100)
• Wire harnesses - Electrical schematic frame 04 Engine Control, Power Shuttle transmission without
options (55.100)
• Wire harnesses - Electrical schematic frame 04 Engine Control, Powershift transmission with op-
tions (55.100)
• Wire harnesses - Electrical schematic frame 04 Engine Control, Powershift transmission without
options (55.100)
47365539 08/07/2012
55.100 / 371

through X-469
CONNECTOR X-461 - ECU

NUMBER
2 G013 (BK) BATTERY MINUS 1
3 E051 (RD) BATTERY +B VIA MAIN RELAY
5 E050 (RD) BATTERY +C VIA MAIN RELAY
7 E070 (YE) LAMBDA SENSOR HEATING
8 E080 (YE) CRANK SIGNAL
9 - -
10 - -
11 - -
12 - -
13 - -
14 E140 (YE) DIFF PRESSURE SUPPLY
15 - -
16 - -
17 - -
18 - -
19 E190 (YE) AIR TEMP SENSOR SIGNAL
20 E200 (BK/WH) AIR TEMP SENSOR GND
21 - -
22 E220 (YE) GLOW PLUG FEEDBACK SIGNAL
23 - -
24 E241 (YE)
25 E251 (GN)
26 - -
29 - -
30 E300 (YE) WATER IN FUEL LEVEL SENSOR SIGNAL
31 - -
32 - -
33 - -
34 - -
35 - -
36 E360 (BK/WH) DIFF PRESSURE SENSOR GND
37 - -
38 - -
39 - -
40 - -
41 E410 (BK) GLOW PLUG UNIT GND
42 - -
43 - -
44 - -
45 - -
46 - -
47 - -
48 - -
49 - -
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NUMBER
50 - -
51 - -
52 E520 (YE) GLOW PLUG UNIT COMMAND SIGNAL
54 1505 (OR) TERMINAL 15 SW BAT+
55 - -
56 - -
57 - -
58 E580 (YE) DIFF PRESSURE SENSOR SIGNAL
59 - -
60 - -
61 - -
62 - -
63 E630 (PK)
64 E640 (YE)
65 - -
66 - -
67 - -
68 E681 (YE) K LINE
69 - -
70 - -
71 - -
72 - -
73 - -
74 - -
75 - -
76 - -
77 - -
78 - -
79 E790 (BK/WH) EXHAUST GAS TEMP GND
80 E800 (YE) EXHAUST GAS TEMP SIGNAL
81 E810 (BK/WH) INLET TURBINE TEMP GND
82 E820 (YE) INLET TURBINE TEMP SIGNAL
83 E830 (BK/WH) EXHAUST GAS TEMP GND 2
84 E840 (YE) EXHAUST GAS TEMP SIGNAL 2
85 E850 (BK)
86 E860 (YE)
87 - -
88 - -
89 - -
90 - -
91 - -
92 - -
93 - -
94 - -
options (55.100)
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options (55.100)
tions (55.100)
options (55.100)
84474047 1
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55.100 / 374

NUMBER
1 F010 (WH)
2 F020 (WH)
3 - -
4 F040 (GY)
5 - -
6 F060 (WH) OIL PRESSURE SWITCH INPUT SIGNAL
7 - -
8 F080 (PK) TVA POSITION SENSOR SUPPLY
9 F090 (PK) EGR POSITION SENSOR SUPPLY
10 F100 (PK) BOOST PRESSURE SENSOR SUPPLY
11 F110 (PK) RAIL PRESSURE SENSOR SUPPLY
12 F120 (PK) EXHAUST GAS PRESSURE SENSOR SUPPLY (UPSTREAM TURBINE
PRESSURE) P3
13 F130 (PK) CAMSHAFT SPEED SENSOR SUPPLY
14 F140 (YE) CAMSHAFT SPEED SENSOR SIGNAL
15 F150 (WH)
16 F160 (WH)
17 F170 (WH)
18 - -
19 - -
20 - -
21 - -
22 - -
23 F230 (BL) FUEL TEMPERATURE SENSOR GROUND
24 F240 (BK/WH) EGR POSITION SENSOR GROUND
25 F250 (BK/WH) BOOST PRESSURE SENSOR GROUND
26 F260 (BL)
27 F270 (BK/WH) EXHAUST GAS PRESSURE SENSOR GROUND P3 (UPSTREAM
TURBINE PRESSURE)
28 F280 (BL) CAMSHAFT SPEED SENSOR GROUND
29 - -
30 - -
31 F310 (GY)
32 F320 (GY)
33 - -
34 F340 (GY)
35 F350 (GY)
36 - -
37 F370 (BK/WH) TVA POSITION SENSOR GROUND
38 F380 (YE) FUEL TEMPERATURE SENSOR SIGNAL
39 F390 (YE) EGR POSITION SENSOR SIGNAL
40 F400 (YE) BOOST PRESSURE SENSOR SIGNAL
41 F410 (YE)
42 - -
43 F430 (YE) EXHAUST GAS PRESSURE SENSOR SIGNAL P3 (UPSTREAM TURBINE
PRESSURE)
44 F440 (YE)
45 - -
46 F460 (GY)
47 - -
48 F480 (GY)
49 F490 (WH)
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NUMBER
50 F500 (WH)
51 - -
52 - -
53 F530 (YE) TVA POSITION SENSOR SIGNAL
54 - -
55 F550 (YE) BOOST PRESSURE TEMPERATURE SENSOR SIGNAL
56 - -
57 F570 (YE) COOLANT TEMPERATURE SENSOR SIGNAL
58 F580 (BL) COOLANT TEMPERATURE SENSOR GROUND
59 F590 (YE)
60 F600 (GY)

options (55.100)
options (55.100)
tions (55.100)
options (55.100)
84474053 2
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55.100 / 376
CONNECTOR X-463 - WATER IN FUEL SWITCH
CONNECTOR X-463 - WATER IN FUEL SWITCH

NUMBER
1 E300 (YE) WATER IN FUEL LEVEL SENSOR SIGNAL
3 1504 (OR) TERMINAL 15 SW BAT+
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
87709663 3
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55.100 / 377
CONNECTOR X-464 - MAIN RELAY
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
84471904 4
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55.100 / 378
CONNECTOR X-466 - GCU FUSE HOLDER 1
CONNECTOR X-466 - GCU FUSE HOLDER

NUMBER
1 F2 ()
2 F1 ()
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
84177914 5
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55.100 / 379
CONNECTOR X-468 - LAMBDA SENSOR
CONNECTOR X-468 - LAMBDA SENSOR

NUMBER
1 E640 (YE)
2 E850 (BK)
3 E070 (YE) LAMBDA SENSOR HEATING
4 E056 (RD) B+ TO LAMBDA SENS
5 E860 (YE)
6 E630 (PK)
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
84301132 6
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55.100 / 380
CONNECTOR X-469 - GCU
CONNECTOR X-469 - GCU

NUMBER
1 1580 (WH) GLOW PLUG
3 E220 (YE) GLOW PLUG FEEDBACK SIGNAL
4 1040 (RD) BAT+
5 E411 (BK) GLOW PLUG UNIT GND
8 E520 (YE) GLOW PLUG UNIT COMMAND SIGNAL
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
84356962 7
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55.100 / 381

through X-479
CONNECTOR X-470 - ENGINE INTERFACE
CONNECTOR X-470 - ENGINE INTERFACE

NUMBER
1 F150 (WH)
2 F600 (GY)
3 F060 (WH) OIL PRESSURE SWITCH INPUT SIGNAL
4 F140 (YE) CAMSHAFT SPEED SENSOR SIGNAL
5 F260 (BL)
6 F410 (YE)
7 F110 (PK) RAIL PRESSURE SENSOR SUPPLY
8 F280 (BL) CAMSHAFT SPEED SENSOR GROUND
9 F590 (YE)
10 F440 (YE)
12 F130 (PK) CAMSHAFT SPEED SENSOR SUPPLY
13 F580 (BL) COOLANT TEMPERATURE SENSOR GROUND
14 F570 (YE) COOLANT TEMPERATURE SENSOR SIGNAL
15 F230 (BL) FUEL TEMPERATURE SENSOR GROUND
16 F380 (YE) FUEL TEMPERATURE SENSOR SIGNAL
17 F100 (PK) BOOST PRESSURE SENSOR SUPPLY
18 F400 (YE) BOOST PRESSURE SENSOR SIGNAL
19 F250 (BK/WH) BOOST PRESSURE SENSOR GROUND
20 F550 (YE) BOOST PRESSURE TEMPERATURE SENSOR SIGNAL
21 F120 (PK) EXHAUST GAS PRESSURE SENSOR SUPPLY (UPSTREAM TURBINE
PRESSURE) P3
22 F270 (BK/WH) EXHAUST GAS PRESSURE SENSOR GROUND P3 (UPSTREAM
TURBINE PRESSURE)
23 F430 (YE) EXHAUST GAS PRESSURE SENSOR SIGNAL P3 (UPSTREAM TURBINE
PRESSURE)
25 E810 (BK/WH) INLET TURBINE TEMP GND
26 E820 (YE) INLET TURBINE TEMP SIGNAL
27 F040 (GY)
28 E058 (RD) B+ TO EL.VALVE
29 F500 (WH)
30 F350 (GY)
33 F090 (PK) EGR POSITION SENSOR SUPPLY
34 F390 (YE) EGR POSITION SENSOR SIGNAL
35 F240 (BK/WH) EGR POSITION SENSOR GROUND
37 F490 (WH)
38 F340 (GY)
41 F080 (PK) TVA POSITION SENSOR SUPPLY
42 F530 (YE) TVA POSITION SENSOR SIGNAL
43 F370 (BK/WH) TVA POSITION SENSOR GROUND
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options (55.100)
options (55.100)
options (55.100)
options (55.100)
tions (55.100)
tions (55.100)
options (55.100)
options (55.100)
84154706 1
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55.100 / 383
CONNECTOR X-471 Injectors
CONNECTOR X-471 — Injectors

NUMBER
A F160 (WH) Injector 1 Driver
B F320 (GY) Injector 1 Return
C F310 (GY) Injector 3 Driver
D F010 (WH) Injector 3 Return
E F170 (WH) Injector 4 Driver
F F480 (GY) Injector 4 Return
G F460 (GY) Injector 2 Driver
H F020 (WH) Injector 2 Return
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
87698252 2
47365539 08/07/2012
55.100 / 384
CONNECTOR X-473 - A/C CLUTCH
CONNECTOR X-473 - A/C CLUTCH

NUMBER
(55.100)
87687239 3
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55.100 / 385
CONNECTOR X-474 - AIR TEMP SENSOR
CONNECTOR X-474 - AIR TEMP SENSOR

NUMBER
1 E190 (YE) AIR TEMP SENSOR SIGNAL
2 E200 (BK/WH) AIR TEMP SENSOR GND
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
84607243 4
47365539 08/07/2012
55.100 / 386
CONNECTOR X-475 - DIFF PRESSURE SENSOR
CONNECTOR X-475 - DIFF PRESSURE SENSOR

NUMBER
1 E140 (YE) DIFF PRESSURE SUPPLY
2 E360 (BK/WH) DIFF PRESSURE SENSOR GND
3 E580 (YE) DIFF PRESSURE SENSOR SIGNAL
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
87747172 5
47365539 08/07/2012
55.100 / 387
CONNECTOR X-476 - GAS TEMP SENSOR 1
CONNECTOR X-476 - GAS TEMP SENSOR

NUMBER
1 E800 (YE) EXHAUST GAS TEMP SIGNAL
2 E790 (BK/WH) EXHAUST GAS TEMP GND
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
87709793 6
47365539 08/07/2012
55.100 / 388

NUMBER
1 E840 (YE) EXHAUST GAS TEMP SIGNAL 2
2 E830 (BK/WH) EXHAUST GAS TEMP GND 2
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
87709793 7
47365539 08/07/2012
55.100 / 389

NUMBER
1 ALT1 (RD) ALTERNATOR BATTERY CABLE
P002 (RD) BATTERY CABLE FROM STARTER B+
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
84138833 8
47365539 08/07/2012
55.100 / 390

through X-489

NUMBER
1 ALT1 (RD) ALTERNATOR BATTERY CABLE
47365539 08/07/2012
55.100 / 391

NUMBER
1 G004 (BK) GROUND BATTERY CABLE
47365539 08/07/2012
55.100 / 392

NUMBER
1 G004 (BK) GROUND BATTERY CABLE
(55.100)
tions (55.100)
(55.100)
(55.100)
47365539 08/07/2012
55.100 / 393

NUMBER
1 G020 (BK) PARK BRAKE SOLENOID GROUND
G021 (BK) FUEL SENDER GROUND
G030 (BK) BACKUP ALARM GROUND
G116 (BK) PILOT CONTROLS GROUND
G157 (BK) MAIN CHASSIS HARNESS GROUND
G158 (BK) MAIN CHASSIS HARNESS GROUND
(55.100)
tions (55.100)
(55.100)
(55.100)
47365539 08/07/2012
55.100 / 394

NUMBER
1 G001 (BK) EH CLAM OUTPUT
G066 (BK) INSTRUMENT CLUSTER GROUND
G076 (BK) DIAGNOSTIC PORT GROUND
G081 (BK) PARK BRAKE RELAY COIL GROUND
G154 (BK) TRAX CONTROLLER POWER GROUND
G160 (BK) SIDE CONSOLE HARNESS GROUND
G179 (BK) EH CLAM GROUND
(55.100)
tions (55.100)
(55.100)
(55.100)
47365539 08/07/2012
55.100 / 395

NUMBER
1 G003 (BK) SHUTTLE INTERLOCK TIMING RELAY GROUND
G005 (BK) CLUTCH RELAY COIL GROUND
G026 (BK) SHUTTLE INTERLOCK RELAY COIL GROUND
G043 (BK) AUTO/MANUAL SWITCH GROUND
G085 (BK) COMFORT STEER SWITCH GROUND
G095 (BK) REAR WINDSHIELD WASHER PUMP GROUND
G096 (BK) FRONT WINDSHIELD WASHER PUMP GROUND
G156 (BK) FRONT CONSOLE HARNESS GROUND
G159 (BK) FRONT CONSOLE HARNESS GROUND
(55.100)
tions (55.100)
(55.100)
(55.100)
47365539 08/07/2012
55.100 / 396

through X-499

NUMBER
A E530 (YE) CRANK ENABLE FROM ECU
B E681 (YE) K LINE
C 150A (OR) IGNITION
D E080 (YE) CRANK SIGNAL
E E251 (GN)
F E270 (YE) CRANK ENABLE FROM ECU
H 60C6 (BR) A/C COMPRESSOR OUTPUT
K E241 (YE)
options (55.100)
(55.100)
options (55.100)
tions (55.100)
options (55.100)
options (55.100)
47365539 08/07/2012
55.100 / 397
87698254 1
47365539 08/07/2012
55.100 / 398

NUMBER
A E172 (YE) CRANK ENABLE FROM ECU
B E682 (YE) K LINE
C 150B (OR) IGNITION
D E081 (YE) CRANK SIGNAL
E E252 (GN) CAN 1 LOW
F E372 (YE) CRANK ENABLE FROM ECU
G - -
H 60C5 (BR) A/C COMPRESSOR OUTPUT
K E242 (YE) CAN 1 HIGH
options (55.100)
(55.100)
options (55.100)
tions (55.100)
options (55.100)
options (55.100)
47365539 08/07/2012
55.100 / 399
87698252 2
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55.100 / 400

NUMBER
A - -
B - -
C - -
D E255 (GN) CAN LO
E E245 (YE) CAN HI
F - -
G - -
H - -
J 1022 (RD) TELEMATICS B+
K - -
L 21A5 (YE) CRANK SIGNAL
M 3404 (YE) ALT SIGNAL
N - -
P - -
R - -
S G324 (BK) TELEMATICS GND
• Wire harnesses - Electrical schematic frame 26 Telematics, Power Shuttle transmission with options
(55.100)
• Wire harnesses - Electrical schematic frame 26 Telematics, Power Shuttle transmission without op-
tions (55.100)
• Wire harnesses - Electrical schematic frame 29 Telematics, Powershift transmission with options
(55.100)
• Wire harnesses - Electrical schematic frame 29 Telematics, Powershift transmission without options
(55.100)
87696550 3
47365539 08/07/2012
55.100 / 401

through X-509

NUMBER
1 1041 (RD) BATT+
P011 (RD) ECU B+
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
47365539 08/07/2012
55.100 / 402

NUMBER
47365539 08/07/2012
55.100 / 403

through X-519

NUMBER
1 G011 (BK) ECU GROUND
(55.100)
tions (55.100)
(55.100)
(55.100)
47365539 08/07/2012
55.100 / 404

NUMBER
AP63 (YE) RIDE CONTROL RELAY
• Wire harnesses - Electrical schematic frame 27 2WD Ride Control Jumper, Power Shuttle transmis-
84277534 1
47365539 08/07/2012
55.100 / 405

NUMBER
options (55.100)
47365539 08/07/2012
55.100 / 406

through X-539

NUMBER
1 21A6 (YE) PUMP COLD START SOL
2 G325 (BK) PUMP COLD START SOL GND
options (55.100)
84426132 1
47365539 08/07/2012
55.100 / 407

through X-609
CONNECTOR X-600 - PT SPEED SENS
CONNECTOR X-600 - PT SPEED SENS

NUMBER
2 G322 (BK) PT SPEED SENS GND
87691928 1
47365539 08/07/2012
55.100 / 408

through X-829

NUMBER
A 21B3 (WH) CRANK OUTPUT
options (55.100)
options (55.100)
tions (55.100)
options (55.100)
87697528 1
47365539 08/07/2012
55.100 / 409
Index

Wire harnesses - Electrical schematic frame 01 Power Distribution/ Charging System, Power Shuttle transmission
without options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
580N NA Power Shuttle, 580N NA T4, 580SN NA Power Shuttle, 580SN NA T4, 580SN WT NA Power Shuttle, 580SN WT NA T4,
590SN NA Power Shuttle, 590SN NA T4
Wire harnesses - Electrical schematic frame 01 Power Distribution/ Charging System, Powershift transmission with
options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
580N NA Powershift, 580N NA T4, 580SN NA Powershift, 580SN NA T4, 580SN WT NA Powershift, 580SN WT NA T4, 590SN NA
Powershift, 590SN NA T4
Wire harnesses - Electrical schematic frame 01 Power Distribution/ Charging System, Powershift transmission with-
out options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Wire harnesses - Electrical schematic frame 02 Starting System, Power Shuttle transmission with options . . . . 20
Wire harnesses - Electrical schematic frame 02 Starting System, Power Shuttle transmission without options . 22
Wire harnesses - Electrical schematic frame 02 Starting System, Powershift transmission with options . . . . . . . 24
Wire harnesses - Electrical schematic frame 02 Starting System, Powershift transmission without options . . . . 26
Wire harnesses - Electrical schematic frame 03 Grounding, Power Shuttle transmission with options . . . . . . . . . 28
Wire harnesses - Electrical schematic frame 03 Grounding, Power Shuttle transmission without options . . . . . . 30
Wire harnesses - Electrical schematic frame 03 Grounding, Powershift transmission with options . . . . . . . . . . . . 32
Wire harnesses - Electrical schematic frame 03 Grounding, Powershift transmission without options . . . . . . . . . 34
Wire harnesses - Electrical schematic frame 04 Engine Control, Power Shuttle transmission with options . . . . . 36
Wire harnesses - Electrical schematic frame 04 Engine Control, Power Shuttle transmission without options . . 38
Wire harnesses - Electrical schematic frame 04 Engine Control, Powershift transmission with options . . . . . . . . 40
Wire harnesses - Electrical schematic frame 04 Engine Control, Powershift transmission without options . . . . . 42
Wire harnesses - Electrical schematic frame 05 Engine Control, Power Shuttle transmission with options . . . . . 44
Wire harnesses - Electrical schematic frame 05 Engine Control, Power Shuttle transmission without options . . 46
Wire harnesses - Electrical schematic frame 05 Engine Control, Powershift transmission with options . . . . . . . . 48
Wire harnesses - Electrical schematic frame 05 Engine Control, Powershift transmission without options . . . . . 50
Wire harnesses - Electrical schematic frame 06 Drives, Power Shuttle transmission with options . . . . . . . . . . . . 52
47365539 08/07/2012
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Wire harnesses - Electrical schematic frame 06 Drives, Power Shuttle transmission without options . . . . . . . . . . 54
Wire harnesses - Electrical schematic frame 06 Powershift Transmission Inputs, Powershift transmission with op-
tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Wire harnesses - Electrical schematic frame 06 Powershift Transmission Inputs, Powershift transmission without
options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Wire harnesses - Electrical schematic frame 07 Hydraulics, Power Shuttle transmission with options . . . . . . . . . 60
Wire harnesses - Electrical schematic frame 07 Hydraulics, Power Shuttle transmission without options . . . . . . 62
Wire harnesses - Electrical schematic frame 07 Hydraulics, Powershift transmission with options . . . . . . . . . . . . 64
Wire harnesses - Electrical schematic frame 07 Hydraulics, Powershift transmission without options . . . . . . . . . 66
Wire harnesses - Electrical schematic frame 08 Pilot Controls, Power Shuttle transmission with options . . . . . . 68
Wire harnesses - Electrical schematic frame 08 Pilot Controls, Power Shuttle transmission without options . . . 70
Wire harnesses - Electrical schematic frame 08 Pilot Controls, Powershift transmission with options . . . . . . . . . 72
Wire harnesses - Electrical schematic frame 08 Pilot Controls, Powershift transmission without options . . . . . . . 74
Wire harnesses - Electrical schematic frame 09 Front Exterior Lights, Power Shuttle transmission with options 76
Wire harnesses - Electrical schematic frame 09 Front Exterior Lights, Power Shuttle transmission without options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Wire harnesses - Electrical schematic frame 09 Front Exterior Lights, Powershift transmission with options . . . 80
Wire harnesses - Electrical schematic frame 09 Front Exterior Lights, Powershift transmission without options 82
Wire harnesses - Electrical schematic frame 10 Interior Lighting, Power Shuttle transmission with options . . . . 84
Wire harnesses - Electrical schematic frame 10 Interior Lighting, Power Shuttle transmission without options . . 86
Wire harnesses - Electrical schematic frame 10 Interior Lighting, Powershift transmission with options . . . . . . . 88
Wire harnesses - Electrical schematic frame 10 Interior Lighting, Powershift transmission without options . . . . . 90
Wire harnesses - Electrical schematic frame 11 Wipers and Washers, Power Shuttle transmission with options 92
Wire harnesses - Electrical schematic frame 11 Wipers and Washers, Power Shuttle transmission without options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Wire harnesses - Electrical schematic frame 11 Windshield Wipers, Powershift transmission with options . . . . . 96
Wire harnesses - Electrical schematic frame 11 Windshield Wipers, Powershift transmission without options . . 98
Wire harnesses - Electrical schematic frame 12 Instrument Cluster, Power Shuttle transmission with options . 100
47365539 08/07/2012
55.100 / 411
Wire harnesses - Electrical schematic frame 12 Instrument Cluster, Power Shuttle transmission without options 102
Wire harnesses - Electrical schematic frame 12 Instrument Cluster, Powershift transmission with options . . . . 104
Wire harnesses - Electrical schematic frame 12 Instrument Cluster, Powershift transmission without options . 106
Wire harnesses - Electrical schematic frame 13 Power Points, Power Shuttle transmission with options . . . . . 108
Wire harnesses - Electrical schematic frame 13 Power Points, Power Shuttle transmission without options . . . 110
Wire harnesses - Electrical schematic frame 13 Power Points, Powershift transmission with options . . . . . . . . 112
Wire harnesses - Electrical schematic frame 13 Power Points, Powershift transmission without options . . . . . . 114
Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Power Shuttle transmission with options . 116
Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Power Shuttle transmission without options 118
Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Powershift transmission with options . . . . 120
Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Powershift transmission without options . 122
Wire harnesses - Electrical schematic frame 15 HVAC, Power Shuttle transmission with options . . . . . . . . . . . . 124
Wire harnesses - Electrical schematic frame 15 HVAC, Power Shuttle transmission without options . . . . . . . . . 126
Wire harnesses - Electrical schematic frame 15 HVAC, Powershift transmission with options . . . . . . . . . . . . . . . 128
Wire harnesses - Electrical schematic frame 15 HVAC, Powershift transmission without options . . . . . . . . . . . . 130
Wire harnesses - Electrical schematic frame 16 Radio, Power Shuttle transmission with options . . . . . . . . . . . . 132
Wire harnesses - Electrical schematic frame 16 Radio, Power Shuttle transmission without options . . . . . . . . . 134
Wire harnesses - Electrical schematic frame 16 Radio, Powershift transmission with options . . . . . . . . . . . . . . . 136
Wire harnesses - Electrical schematic frame 16 Radio, Powershift transmission without options . . . . . . . . . . . . 138
Wire harnesses - Electrical schematic frame 17 Rear Lights Exterior, Power Shuttle transmission with options 140
Wire harnesses - Electrical schematic frame 17 Rear Lights Exterior, Power Shuttle transmission without options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Wire harnesses - Electrical schematic frame 17 Rear Exterior Lights, Powershift transmission with options . . . 144
Wire harnesses - Electrical schematic frame 17 Rear Lights Exterior, Powershift transmission without options 146
Wire harnesses - Electrical schematic frame 18 Options, Power Shuttle transmission with options . . . . . . . . . . 148
Wire harnesses - Electrical schematic frame 18 Options, Power Shuttle transmission without options . . . . . . . 150
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Wire harnesses - Electrical schematic frame 18 Options, Powershift Transmission with options . . . . . . . . . . . . . 152
Wire harnesses - Electrical schematic frame 18 Options, Powershift transmission without options . . . . . . . . . . . 154
Wire harnesses - Electrical schematic frame 19 Horn, Power Shuttle transmission with options . . . . . . . . . . . . . 156
Wire harnesses - Electrical schematic frame 19 Horn, Power Shuttle transmission without options . . . . . . . . . . 158
Wire harnesses - Electrical schematic frame 19 Horn, Powershift transmission with options . . . . . . . . . . . . . . . . 160
Wire harnesses - Electrical schematic frame 19 Horn, Powershift transmission without options . . . . . . . . . . . . . 162
Wire harnesses - Electrical schematic frame 20 Comfort Steer/ Ride Control, Power Shuttle transmission with op-
tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Wire harnesses - Electrical schematic frame 20 Comfort Steer/ Ride Control, Power Shuttle transmission without
options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Wire harnesses - Electrical schematic frame 20 Comfort Steer/ Ride Control, Powershift transmission with options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Wire harnesses - Electrical schematic frame 20 Comfort Steer/ Ride Control, Powershift transmission without op-
tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Wire harnesses - Electrical schematic frame 21 Hydraulic Options Powerlift, Power Shuttle transmission with op-
tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Wire harnesses - Electrical schematic frame 21 Hydraulic Options Powerlift, Power Shuttle transmission without
options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Wire harnesses - Electrical schematic frame 21 Canopy Exterior Lights, Powershift transmission with options 176
Wire harnesses - Electrical schematic frame 21 Canopy Exterior Lights, Powershift transmission without options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Wire harnesses - Electrical schematic frame 22 Pilot Controls Inputs, Power Shuttle transmission with options 180
Wire harnesses - Electrical schematic frame 22 Pilot Control Inputs, Power Shuttle transmission without options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Wire harnesses - Electrical schematic frame 22 Powershift Transmission Jumper Harness, Powershift transmission
with options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Wire harnesses - Electrical schematic frame 22 Powershift Transmission Jumper Harness, Powershift transmission
without options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Wire harnesses - Electrical schematic frame 23 Combo/ Aux/ Uni Hydraulics, Power Shuttle transmission with op-
tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Wire harnesses - Electrical schematic frame 23 Combo/ Aux/ Uni Hydraulics, Power Shuttle transmission without
options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
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Wire harnesses - Electrical schematic frame 23 TRAX Powershift Controller, Powershift transmission with options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Wire harnesses - Electrical schematic frame 23 TRAX Powershift Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Wire harnesses - Electrical schematic frame 24 Canopy Exterior Lights, Power Shuttle transmission with options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Wire harnesses - Electrical schematic frame 24 Canopy Exterior Lights, Power Shuttle transmission without options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Wire harnesses - Electrical schematic frame 24 Hydraulic PowerLift, Powershift transmissions with options . . 200
Wire harnesses - Electrical schematic frame 24 Hydraulic PowerLift, Powershift transmission without options 202
Wire harnesses - Electrical schematic frame 25 Can Bus/ Diagnostics, Power Shuttle transmission with options 204
Wire harnesses - Electrical schematic frame 25 Can Bus/ Diagnostics, Power Shuttle transmission without options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Wire harnesses - Electrical schematic frame 25 Combo Hydraulics, Powershift transmission with options . . . . 208
Wire harnesses - Electrical schematic frame 25 Combo Hydraulics, Powershift transmission without options . 210
Wire harnesses - Electrical schematic frame 26 Telematics, Power Shuttle transmission with options . . . . . . . . 212
Wire harnesses - Electrical schematic frame 26 Telematics, Power Shuttle transmission without options . . . . . 214
Wire harnesses - Electrical schematic frame 26 Pilot Control Inputs, Powershift transmission with options . . . 216
Wire harnesses - Electrical schematic frame 26 Pilot Control Inputs, Powershift transmission without options . 218
Wire harnesses - Electrical schematic frame 27 2WD Ride Control Jumper, Power Shuttle transmission with options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Wire harnesses - Electrical schematic frame 27 Accessory Jumpers, Power Shuttle transmission without options
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Wire harnesses - Electrical schematic frame 27 Accessory Jumpers, Powershift transmission with options . . . 224
Wire harnesses - Electrical schematic frame 27 Accessory Jumpers, Powershift transmission without options 226
Wire harnesses - Electrical schematic frame 28 Accessory Jumpers, Power Shuttle transmission with options 228
Wire harnesses - Electrical schematic frame 28 CAN Bus/ Diagnostics, Powershift transmission with options . 230
Wire harnesses - Electrical schematic frame 28 CAN Bus/ Diagnostics, Powershift transmission without options 232
Wire harnesses - Electrical schematic frame 29 Telematics, Powershift transmission with options . . . . . . . . . . . 234
Wire harnesses - Electrical schematic frame 29 Telematics, Powershift transmission without options . . . . . . . . 236
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Wire connectors - Component Diagram 00 – Connectors X-001 through X-009 . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
580N NA Powershift, 580N NA Power Shuttle, 580N NA T4, 580SN NA Powershift, 580SN NA Power Shuttle, 580SN NA T4, 580SN
WT NA Powershift, 580SN WT NA Power Shuttle, 580SN WT NA T4, 590SN NA Powershift, 590SN NA Power Shuttle, 590SN NA T4
Wire connectors - Component diagram 01 – Connectors X-010 through X-019 . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
Wire connectors - Component diagram 11 – Connectors X-110 through X-119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
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Wire harnesses - Electrical schematic frame 01 Power Distribution/ Charging System, Power Shuttle transmission
with options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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Engine starting system - 201
580N
580SN WT
580SN
590SN
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Contents
TECHNICAL DATA
Engine starting system

FUNCTIONAL DATA
Engine starter
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Engine starting system

Remove - Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install - Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Engine starter
Starter solenoid - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Starter solenoid - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Starter solenoid - Test - Field coil test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Starter solenoid - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Starter solenoid - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
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Electrical systems - Engine starting system
Engine starting system - General specification

SPECIFICATIONS
Manufacturer Nippondenso
No-Load Test at 20 °C (68.0 °F)
Volts 11 V
Current draw 200 A maximum
Starter drive speed 3000 RPM minimum
LUBRICATION
Interval When the starter is disassembled or each time the
engine is removed for repairs
Lubricant
Molykote-GN Use on shaft at pinion end of starter drive
Case multipurpose grease Use on bearings, gears, idler gear shaft and spring
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Engine starter - Exploded view
RCPH10TLB062GAL 1
1. Bolt 9. Armature 17. Idler gear

2. Lock washer 10. Field frame 18. Roller (5)
3. Flat washer 11. Cover 19. Bearing cage
4. O-ring 12. Gasket 20. Spring
5. Screw 13. Plunger 21. Steel ball
6. Cover 14. Nut 22. Starter drive
7. Brush holder 15. Starter solenoid assembly 23. Starter drive housing
8. Bearing 16. Thrust washer
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Engine starting system - Remove - Starter

Prior operation:
NOTE: The starter is located on the engine flywheel hous-

ing.
parking brake.
2. Remove the pin that fastens the support strut to the
loader frame.
3. Raise the loader frame until the support strut is
against the end of the lift cylinder.
4. Stop the engine and install the pin in the support
strut.
RCPH11TLB001AAM 1
5. Remove the bolts and washers that fasten the battery

cover to the right side of the machine by the step.
7. A. Remove the negative battery cable (2) from the
battery. Move the cable away from the battery
terminals.
B. Remove the positive battery cable (1) from the
battery. Move the cable away from the battery
terminals.
RCPH10TLB429AAF 2
8. Open the hood.
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9. Tag and disconnect the wires and cables from the

terminals on the starter.
NOTE: Starter wire is coated with RTV silicone sealant.
RCPH10TLB232ABL 3
10. Remove the two bolts (1) that fasten the starter to the
flywheel housing. Remove the starter.
RCPH10TLB230ABL 4
Next operation:
Engine starting system - Install (55.201)
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Engine starting system - Install - Starter

Prior operation:
Engine starting system - Remove (55.201)
1. Put the starter in place on the flywheel housing.

2. Install the bolts (1) that fasten the starter to the fly-
wheel housing. Make sure the ground cable (2) is
installed under the upper bolt. Torque bolts to 40 -
47 N·m (29.5 - 34.7 lb ft).
RCPH10TLB230ABL 1
3. Connect the wires and cables to the terminals on the

starter.
RCPH10TLB232ABL 2
4. Cover the starter wire terminal with 737 RTV silicone

sealant.
NOTICE: Use only 737 RTV silicone sealant. Other
sealants can corrode the terminal.
5. Close the hood.
6. Reconnect the positive battery cable (1) to the bat-
tery.
7. Reconnect the negative battery cable (2) to the bat-
tery.
RCPH10TLB429AAF 3
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8. Install the battery cover.
RCPH11TLB002AAM 4
9. Install the washers and bolts that fasten the battery

cover to the machine.
RCPH11TLB001AAM 5
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Engine starting system - Test

General information
1. The No-Load Test is done with the starter re-
moved from the engine.
2. Check to see if you can pull the gear on the
starter drive out of the starter drive housing.
3. Check to see if the starter drive can be turned.
Pull the gear on the starter drive out of the
starter drive housing. Turn the gear to turn the
starter drive and the armature.
4. If the starter drive cannot be turned, disassem-
ble the starter and make repairs as needed.
Then do the No-Load Test.
Test equipment
The No-Load Test can be done using a Sun Electric
VAT-33 Tester, an equivalent tester, or separate pieces of
test equipment.
A hand held tachometer is needed to measure the speed
of the armature shaft.
A remote starter button is needed to actuate the starter.
A fully charged 12 volt battery is needed to supply the elec-
tricity to turn the starter.
Test procedure
The illustrations in this procedure show the use of the Sun
Electric VAT-33 tester. Other test equipment can be used.
Connect the test equipment according to this procedure
and the manufacturer’s instructions.
1. If the VAT-33 tester is being used:
A. Select the 0 - 100 A range.
B. Select the 18 - 40 V range.
C. Move the volt lead switch to the EXT. position.
D. Turn the load control to the OFF position.
RCPH10TLB220ABL 1
2. Fasten the starter in a vise or use another method to

prevent the starter from moving. This must be done
to prevent personal injury.
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3. Connect the positive battery cable (1) to the battery

terminal (2) on the starter solenoid and the negative
battery cable (3) to the mounting flange of the starter.
RCPH10TLB221ABL 2
4. Connect the positive load cable (1) to the positive

post of the battery. Connect the negative load cable
(2) to the negative post.
RCPH10TLB222ABL 3
5. Connect the red voltmeter lead (1) to the motor ter-

minal (2) on the starter solenoid.
RCPH10TLB223ABL 4
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6. Connect the black voltmeter lead (1) the mounting

flange on the starter.
RCPH10TLB224ABL 5
7. Fasten the ammeter clamp (1) around the positive

battery cable so that the tip of the arrow is toward
the starter.
RCPH10TLB225ABL 6
8. Connect the leads from the remote starter button (1)

to the battery (2) and switch terminals (3).
RCPH10TLB226ABL 7
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NOTICE: Steps 9, 10, and 11 must be done rapidly. Do not load the battery for more than 15 s at one time. After the
battery has been loaded for 15 s let the starter cool for 60 s.
9. Actuate the remote starter button (1) and turn the
load control (2) until the voltmeter (3) indicates 11 V.
RCPH10TLB227ABL 8
10. Look at the ammeter (4) and make a record of the

ammeter indication.
11. Use the hand held tachometer (5) and check the ar-
mature shaft speed. Make a record of armature shaft
speed.
12. Release the remote starter button and turn the load
control to the OFF position.
Understanding no load test results

1. If the current draw and the armature shaft speed are
within the ranges under Specifications, the starter is
good.
2. Low armature shaft speed and high current draw are
indications of too much friction. Possible causes of
too much friction are:
A. Tight, dirty, or worn bearings.
B. A bent armature shaft.
C. Loose pole shoes (pole shoes make contact
with the armature).
D. A short circuit in the armature coil. Disassem-
ble the starter. Use an armature tester to test
the armature. Use the instructions included
with the armature tester.
E. Damaged field coil. Refer to Engine starter
Starter solenoid - Test (55.201).
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3. If the armature does not rotate and the current draw

is high, possible causes are:
A. Field terminal making contact with the field
frame. Inspect the insulators for the field ter-
minal.
B. Damaged field coil. Refer to Engine starter
Starter solenoid - Test (55.201)
C. Damaged bearings.
4. If the armature does not rotate and the current draw
is zero, possible causes are:
A. An open field circuit. Disassemble the starter
and inspect the field coil connections.
B. An open armature coil. Disassemble the starter
and check for burned commutator bars. Use an
armature tester to test the armature. Use the
instructions included with the armature tester.
C. Brushes not making good contact with the
commutator bars. Check for high insulation
between the commutator bars, broken brush
springs, or worn brushes.
5. Low armature shaft speed and low current draw are
indications of:
A. Dirt or corrosion on connections.
B. Damaged wiring.
C. Dirty commutator bars.
D. All causes in step 4.
6. High armature shaft speed and high current draw are
indications of a short circuit in the field coil. It is
difficult to find a short circuit in a field coil. Install a
new field coil. Do the No Load Test again to check
for improvement in the operation of the starter.
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Engine starter Starter solenoid - Remove

1. Pull back the boot on the motor terminal and loosen
and remove the nut and lock washer.
RCPH10TLB185ABL 1
2. Loosen and remove the screws that mount and hold

the brush holder to the cover.
RCPH10TLB186ABL 2
3. Loosen and remove the bolts.
RCPH10TLB187ABL 3
RCPH10TLB188ABL 4
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5. Hold the spring away from one of the brushes con-

nected to the field coil and remove the brush from
the brush holder. Repeat this step for the other brush
connected to the field coil.
RCPH10TLB189ABL 5
6. Remove the brush holder.
RCPH10TLB190ABL 6
7. Remove the field frame assembly.
RCPH10TLB191ABL 7
8. Remove the armature.
RCPH10TLB192ABL 8
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9. Fasten the starter solenoid in a vise and loosen and

remove the screws that hold the starter drive hous-
ing.
RCPH10TLB193ABL 9
10. Remove the starter drive housing from the starter

solenoid.
RCPH10TLB194ABL 10
11. Push down the starter drive housing as shown to

loosen and remove the starter drive.
RCPH10TLB195ABL 11
12. Remove the steel ball from the starter drive. If nec-
essary, use a magnet.
RCPH10TLB196ABL 12
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13. Remove the O-ring from the groove in the starter

drive housing.
RCPH10TLB171ABL 13
RCPH10TLB172ABL 14
15. Remove the idler gear.
RCPH10TLB173ABL 15
16. Remove the bearing cage.
RCPH10TLB174ABL 16
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RCPH10TLB175ABL 17
18. Loosen and remove the screws that hold the cover.
RCPH10TLB176ABL 18
19. If necessary, use a hammer to loosen the cover.
RCPH10TLB177ABL 19
RCPH10TLB178ABL 20
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21. Remove the plunger.
RCPH10TLB179ABL 21
22. If necessary, remove the gasket from the cover.
RCPH10TLB180ABL 22
Next operation:
Engine starter Starter solenoid - Inspect (55.201)
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Engine starter Starter solenoid - Inspect

Prior operation:
Engine starter Starter solenoid - Remove (55.201)
Inspection
All parts except the starter drive must be cleaned using
mineral spirits and a brush or cloth. Use a clean, dry cloth
to clean the starter drive.
Brushes and brush springs

1. If the length of a brush that is attached to the brush
holder is less than 11 mm (0.433 in) a new brush
holder assembly must be used when the starter is
assembled.
2. If the length of a brush that is attached to the field coil
is less than 11 mm (0.433 in) a new field frame as-
sembly must be used when the starter is assembled.
3. Use a spring scale to check the tension of the brush
springs. Pull the brush spring up until the brush
spring is just above the brush holder. The scale indi-
cation must be between 1.8 - 4.1 kg (4.0 - 9.0 lb). If
a brush spring is not as specified, use a new brush
spring when the starter is assembled.
Brush holder
1. Hold the leads of an ohmmeter against the frame and
the brush holders that have insulation between the
brush holder and frame.
2. The needle of the ohmmeter must not move, if the
needle moves replace the brush holder.
RCPH10TLB170ABL 1
Armature
1. Test the armature on an armature tester. Use the
equipment manufacturer’s instructions.
2. Put the armature on vee-blocks as shown and check
the runout of the armature with a dial indicator. The
runout must not be more than 0.05 mm (0.002 in).
RCPH10TLB228ABL 2
47365539 08/07/2012
55.201 / 20
3. If necessary, put the armature in a lathe and remove

enough material from the commutator to make the
runout less than 0.05 mm (0.002 in).
4. Measure the diameter of the commutator. If the di-
ameter is less than 35 mm (1.378 in) install a new
armature.
5. If the depth of the groove between the commutator
bars is less than 0.2 mm (0.008 in), cut the insulation
between the commutator bars to a depth of 0.4 - 0.8
mm (0.016 - 0.031 in). Use sandpaper to remove
the rough edges from the commutator bars.
RCPH10TLB169ABL 3
6. Check the bearings on the armature for free rotation,

rough balls, and damage to the inner race or outer
race. If a bearing is to be replaced, use a press and
acceptable tools to remove and install the bearings.
Next operation:
Engine starter Starter solenoid - Install (55.201)
47365539 08/07/2012
55.201 / 21
Engine starter Starter solenoid - Test - Field coil test

1. Hold one of the leads of an ohmmeter against the
field frame. Hold the other lead of the ohmmeter
against one of the brushes and look at the ohmme-
ter. Move the lead that is on the brush to the other
brush and look at the ohmmeter. The needle of the
ohmmeter must not move when the lead is in either
position. If the needle of the ohmmeter moved, in-
stall a new field frame assembly.
RCPH10TLB218ABL 1
2. Hold one of the leads of the ohmmeter against the

end of the cable. Hold the other lead of the ohmme-
ter against one of the brushes and look at the ohm-
meter. Move the lead that is on the brush to the other
brush and look at the ohmmeter. The needle of the
ohmmeter must move when the lead is in both posi-
tions. If the needle of the ohmmeter did not move,
install a new field frame assembly.
RCPH10TLB219ABL 2
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Engine starter Starter solenoid - Install

Prior operation:
Engine starter Starter solenoid - Inspect (55.201)
1. Install the plunger in the starter solenoid.
RCPH10TLB179ABL 1
2. If necessary, install a new gasket in the cover.
RCPH10TLB181ABL 2
3. Install the cover.
RCPH10TLB178ABL 3
4. Install and tighten the screws.
RCPH10TLB182ABL 4
47365539 08/07/2012
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5. Install the bearings in the bearing cage.
RCPH10TLB183ABL 5
6. Lubricate the bearings and teeth of the idler gear with

the grease specified in Engine starting system -
RCPH10TLB184ABL 6
RCPH10TLB212ABL 7
8. Install the bearing cage as shown.
RCPH10TLB213ABL 8
47365539 08/07/2012
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9. Install the idler gear.
RCPH10TLB214ABL 9
RCPH10TLB215ABL 10
11. Install a new O-ring in the groove in the starter drive

housing. Lubricate the O-ring with the grease spec-
ified in Engine starting system - General specifi-
cation (55.201).
RCPH10TLB216ABL 11
12. Lubricate the open bearing on the starter drive with

the grease specified in Engine starting system -
RCPH10TLB217ABL 12
47365539 08/07/2012
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13. Start the starter drive into the starter drive housing.
RCPH10TLB197ABL 13
14. Push down the starter drive housing to push the

starter drive all the way into the starter drive housing.
RCPH10TLB198ABL 14
15. Put a small amount of grease in the hole in the starter

drive and install the steel ball in the hole.
RCPH10TLB199ABL 15
16. Assemble the starter drive housing and starter sole-

noid.
RCPH10TLB194ABL 16
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17. Install a lock washer, flat washer, and O-ring on the

screws that hold the starter drive housing. Lubricate
the O-rings with the grease specified in Engine start-
ing system - General specification (55.201).
RCPH10TLB200ABL 17
18. Install the screws in the starter drive housing.
RCPH10TLB201ABL 18
19. Fasten the starter solenoid in the vise and tighten the
screws that hold the starter drive housing.
RCPH10TLB193ABL 19
20. Install the armature.
RCPH10TLB192ABL 20
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21. Install the field frame assembly.
RCPH10TLB191ABL 21
22. Use the springs to hold the brushes in the brush

holder as shown.
RCPH10TLB202ABL 22
23. Install the brush holder.
RCPH10TLB203ABL 23
24. Put the springs on top of the brushes connected to

the brush holder.
RCPH10TLB204ABL 24
47365539 08/07/2012
55.201 / 28
25. Install the brushes that are connected to the field coil.
RCPH10TLB205ABL 25
26. Use a bolt to align the brush holder with the field
frame assembly.
RCPH10TLB206ABL 26
27. Move the brush holder so that the brush holder is

even with the end of the armature.
RCPH10TLB207ABL 27
28. Install the cover and align the cover with the brush
holder.
RCPH10TLB208ABL 28
47365539 08/07/2012
55.201 / 29
29. Install and tighten the screws that hold the brush
holder.
RCPH10TLB209ABL 29
30. Install a lock washer, flat washer, and O-ring on the

bolts. Lubricate the O-rings with the grease specified
in Engine starting system - General specification
(55.201).
RCPH10TLB210ABL 30
31. Install and tighten the bolts.
RCPH10TLB211ABL 31
32. Install the cable, lock washer, and nut on the motor
terminal, and tighten the nut.
RCPH10TLB185ABL 32
33. Pull the boot over the motor terminal.
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Engine starter Starter solenoid - Test

This test will check the condition of the pull-in winding and
the hold-in winding in the starter solenoid.
The jumper cable connected to the starter mounting flange
and the motor terminal must have a common connection at
the negative battery post.
Starter solenoid test procedure

1. Remove the rubber boot from the motor terminal.
Remove the nut and lock washer from the motor ter-
minal. Then remove the wire from the motor terminal.
2. Connect a jumper cable to the positive battery post
of a fully charged 12 volt battery. Connect the other
end of the jumper cable to the battery terminal on the
starter solenoid housing.
RCPH10TLB229ABL 1
1. 12 Volt battery 4. Switch terminal

2. Starter 5. Motor terminal
3. Battery terminal
3. Connect a jumper wire to the battery terminal and the

switch terminal in the starter solenoid housing. The
jumper wire must be made from No. 10 or larger wire.
4. Connect the jumper cable with the common connec-
tion to the starter mounting flange and the motor ter-
minal in the starter solenoid housing.
NOTE: Steps 5 and 7 must be done in a maximum of 5 seconds to prevent damage to the pull-in winding and the
hold-in winding.
5. Connect the jumper cable with the common connec-
tion to the negative battery post. The pinion gear on
the starter drive must come all the way out rapidly
and with force.
6. If the pinion gear did not come out rapidly and with
force, the pull-in winding is damaged. The complete
starter solenoid housing assembly must be replaced.
7. Disconnect the jumper cable from the motor terminal
in the starter solenoid housing. The pinion gear on
the starter drive must not move toward the starter
drive housing.
8. If the pinion gear started to move toward the starter
drive housing, the hold-in winding is damaged. The
complete starter solenoid housing assembly must be
replaced.
47365539 08/07/2012
55.201 / 31
Index

Engine starter - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine starter Starter solenoid - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Engine starter Starter solenoid - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Engine starter Starter solenoid - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine starter Starter solenoid - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Engine starter Starter solenoid - Test - Field coil test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Engine starting system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Engine starting system - Install - Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Engine starting system - Remove - Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine starting system - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Alternator - 301
580N
580SN WT
580SN
590SN
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Contents
Alternator - 301
SERVICE
Alternator
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N Powershift, 580N Power Shuttle, 580SN Powershift, 580SN Power Shuttle, 580SN WT Powershift, 580SN WT
Power Shuttle, 590SN Powershift, 590SN Power Shuttle
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
580N Powershift, 580N Power Shuttle, 580SN Powershift, 580SN Power Shuttle, 580SN WT Powershift, 580SN WT
Power Shuttle, 590SN Powershift, 590SN Power Shuttle
DIAGNOSTIC
Alternator
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
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Electrical systems - Alternator
Alternator - Remove
580N Powershift, 580N Power Shuttle, 580SN Powershift, 580SN Power Shuttle, 580SN WT Powershift, 580SN WT Power Shuttle, 590SN Powershift,
590SN Power Shuttle
NOTE: The alternator is located behind the fan on the en-

gine housing.
parking brake.
2. Remove the pin that fastens the support strut to the
loader frame.
3. Raise the loader frame until the support strut is
against the end of the lift cylinder.
4. Stop the engine and install the pin in the support
strut.
RCPH10TLB227AAF 1

RCPH11TLB001AAM 2
RCPH11TLB002AAM 3
47365539 08/07/2012
55.301 / 3
7. Remove the negative cable (2) from the battery post.

Move the cable away from the battery terminals.
8. Remove the positive cable (1) from the battery. Move
the cable away from the battery terminals.
RCPH10TLB429AAF 4
9. Open the hood.
RCPH10TLB356AAF 5
10. Install a breaker bar in the bracket for the tension

pulley.
11. Use the breaker bar to move the tension pulley just
far enough to release tension on the drive belt and
remove the drive belt from the alternator.
12. Tag and disconnect all wires and cable from the al-
ternator. Remove the bolt that fastens the alternator
to the brace. Hold the alternator and remove the bolt
from the top of the alternator.
13. Remove the alternator from the mounting bracket.
RCPH10TLB231ABL 6
(1) Wires (3) Bolt

(2) Bolt (4) Spacer
Next operation:
Alternator - Install (55.301)
47365539 08/07/2012
55.301 / 4
Alternator - Install
580N Powershift, 580N Power Shuttle, 580SN Powershift, 580SN Power Shuttle, 580SN WT Powershift, 580SN WT Power Shuttle, 590SN Powershift,
590SN Power Shuttle
Prior operation:
Alternator - Remove (55.301)
1. Hold the alternator in alignment with the mounting

bracket and install the bolt at the top of the alternator.
Do not tighten the bolt. Install the bolt that fastens
the alternator to the brace. Tighten both of the bolts.
Install the wires and cables on the alternator.
RCPH10TLB231ABL 1
(1) Wires (3) Bolt

(2) Bolt (4) Spacer
2. Use the breaker bar to move the tension pulley just

far enough to install the drive belt. Install the drive
belt on the alternator.
3. Remove the breaker bar.
4. Close the hood.
5. Connect the positive battery cable (1) to the positive
post on the battery.
6. Connect the negative battery cable (2) to the nega-
tive post on the battery.
RCPH10TLB429AAF 2

47365539 08/07/2012
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Alternator - Testing
580N T4, 580SN T4, 580SN WT T4, 590SN T4

Turn the key switch OFF. The connections are secure. The The connections are not secure or
Check connections are free of corrosion, the connections show signs of corro-
Verify the battery connections are abrasion and damage. sion, abrasion and damage. Repair
tight and secure. Check the wiring as required.
and connections for corrosion, abra-
sion and damage. Verify that the
chassis ground frame connections
are secure and tight and free of oil,
paint, dirt, damage and debris.
Turn the key switch OFF. The resistance should be less than The resistance is greater than 10 Ω,
Check 10 Ω. there is a problem with the chassis
Measure the resistance from the ground connection to the alternator.
alternator case connection to the Repair as required.
GND002 minus battery connection.
Check 10 Ω. there is a problem with the connec-
Measure the resistance from the al- tion between the alternator and the
ternator B+ terminal to the Starter B+ starter. Verify that the cable con-
terminal. nections are secure and tight. Verify
that the connections are free of cor-
rosion, abrasion, damage and incor-
rect attachment. Repair as required.
Check 10 Ω. there is a problem with the connec-
Measure the resistance from the Al- tion between the alternator and the
ternator connector pin 3 to the Trax TEL connector pin D. Verify that the
connector pin 53. cable connections are secure and
tight. Verify that the connections are
free of corrosion, abrasion, damage
and incorrect attachment. Repair as
required.
Turn the key switch ON. The voltage should be between 12 If The voltage is less than 12
Check volts and 14.8 volts. volts there is a problem with bat-
Measure the voltage from the al- tery. Repair as required. Refer to
ternator B+ connection to chassis 1015-Battery charge voltage too
ground. Measure the voltage from low (55.000) If The voltage is greater
the Alternator connector pin 3 to than 14.8 volts there is a problem
chassis ground. with alternator. Repair as required.
Refer to 1014-Battery charge volt-
age too high (55.000).
47365539 08/07/2012
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RCPH11TLB056FAL 1
Schematic Legend
(1) Alternator (5) TRAX Controller, connector X-300 pin 53
31S1 YE Alternator connector pin 3
Powershift transmission only
(2) B+ from starter (6) Telematics alternator signal 3404 YE
ALT1 RD Alternator connector pin 1 3401 YE
(3) Alternator connector, X-083 (7) Alternator signal to Instrument Cluster 3403
YE
Alternator connector pin 1 3401 YE
(4) Key switch B+, Alternator excitation
1501 OR Alternator connector, pin 2
47365539 08/07/2012
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Index
Alternator - 301
Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
580N Powershift, 580N Power Shuttle, 580SN Powershift, 580SN Power Shuttle, 580SN WT Powershift, 580SN WT Power Shuttle,
590SN Powershift, 590SN Power Shuttle
Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N Powershift, 580N Power Shuttle, 580SN Powershift, 580SN Power Shuttle, 580SN WT Powershift, 580SN WT Power Shuttle,
590SN Powershift, 590SN Power Shuttle
Alternator - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
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Battery - 302
580N
580SN WT
580SN
590SN
47365539 08/07/2012
55.302 / 1
Contents
Battery - 302
SERVICE
Battery
Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Inspect and clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSTIC
Battery connect/disconnect system

Battery switch - Testing - Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
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Electrical systems - Battery
Battery - Service instruction

Electrolyte Level
If the battery is a maintenance free battery, check the
level of the electrolyte every 1000 hours of operation or
six months, whichever occurs first. For all other batter-
ies, check the level of the electrolyte every 250 hours of
operation.
NOTE: A maintenance free battery will have the words
Maintenance Free on the decal on the top of the battery. If
the center part of the decal has been removed for access to
the battery caps, it is possible that the words Maintenance
Free have been removed from the decal.
RCPH10TLB291AAF 1
Check the level of the electrolyte more often during hot

weather. The use of a large amount of water by the battery
can be caused by high battery temperature or a voltage
regulator setting that is too high. Keep the electrolyte level
above the top of the plates in the battery at all times to
prevent damage to the battery.
NOTE: On maintenance free batteries it is necessary to
remove the center part of the decal for access to the battery
caps. Do not discard the center part of the decal. Install
the center part of the decal after the battery caps have been
installed.
RCPH11TLB080AAL 2
If the level of the electrolyte is low, add distilled water or

other clean water until the electrolyte is just below the cell
opening. Do not add more water than is needed. Too much
water can cause bad performance, a short service life, and
corrosion around the battery.
NOTE: Add water only. DO NOT add electrolyte.
47365539 08/07/2012
55.302 / 3
Battery - Inspect and clean

If damage causes an electrolyte leak, replace the battery.
Inspect the battery at regular intervals for dirt, corrosion,
and damage. Electrolyte and dirt on the top of the battery
can cause the battery to discharge by making a passage
for the current to flow.
If the battery must be cleaned, remove the battery from
the battery carrier and clean the battery, cable terminals,
and the battery carrier. When available, use Case Battery
Saver and Cleaner according to the instructions on the con-
tainer. Case Battery Saver and Cleaner also helps prevent
corrosion. If Case Battery Saver and Cleaner is not avail-
able, use baking soda and water as a cleaner. Do not per-
mit any type of cleaner to enter the cells of the battery.
Install the battery in the machine and make sure the fas-
teners are tight. Apply Case Battery Saver and Cleaner or
Urethane Seal Coat to the cable terminals to prevent corro-
sion. See the Parts Counter Catalog. Do not apply grease.
47365539 08/07/2012
55.302 / 4
Battery - Test
Visual Checks
1. Verify the cable connections are clean and tight. Ver-
ify the cables and connections are free of corrosion,
abrasion, damage and incorrect attachment. Clean
foreign material from the top of the battery.
2. Inspect the battery case, battery posts, and cables
for damage.
3. Check the electrolyte level. Refer to Battery - Ser-
vice instruction (55.302) for details.
4. If you added water to the battery, the battery must be
charged for 15 minutes at 15 - 25 A to mix the water
with the electrolyte.
Specific Gravity Check

A hydrometer is used to check the specific gravity (weight)
of the electrolyte. The specific gravity is an indication of
the level of charge for each cell.
Hydrometers are made to show the correct specific gravity
when the temperature of the electrolyte is 26.7 °C (80 °F).
When you check the specific gravity, you must know the
temperature of the electrolyte. If your hydrometer does not
have a thermometer, get a thermometer to check the tem-
perature of the electrolyte. The thermometer must indicate
a high temperature of at least 52 °C (126 °F).
1. Remove enough electrolyte from a cell so that the
float is free in the tube.
NOTE: If the specific gravity cannot be checked without
first adding water to the cell, the battery must be charged
for 15 minutes at 15 - 25 A to mix the water with the elec-
trolyte. Then check the specific gravity.
2. Read the float.
3. Read the thermometer. If the reading is above 26.7
°C (80 °F) add specific gravity points to the reading
for specific gravity. If the reading is below 26.5 °C (80
°F) subtract specific gravity points from the reading
for specific gravity. See the following illustration and
add or subtract specific gravity points as needed.
4. Make a record of the corrected specific gravity read-
ing for each cell.
5. If the difference between the high reading and the
low reading is 0.050 or more, charge the battery and
check the specific gravity again. If after charging, the
difference is still 0.050 or more, install a new battery.
6. The corrected specific gravity reading shows the
level of charge for the cell. The level of charge must
be at least 75% in each of the cells. In maintenance
free batteries the level of charge is at least 75%
if the corrected specific gravity reading is 1.240 or
higher. In all other batteries the level of charge is at
least 75% if the corrected specific gravity reading is
1.230 or higher.
47365539 08/07/2012
55.302 / 5
7. If the difference between the high reading and the low

reading is less than 0.050, and the level of charge is
at least 75% in all of the cells, perform the Capacity
(Load) Test in this section.
8. If the difference between the high reading and the low
reading is less than 0.050, but the level of charge is
less than 75% in any of the cells, charge the battery
and check the specific gravity again. If after charg-
ing:
A. The level of charge is less than 75% in any of
the cells, replace the battery.
B. The level of charge is at least 75% in all of the
cells, perform the Capacity (Load) Test.
Capacity (Load) Test

This test can be done using a variable load tester such as
the CAS10147. Other test equipment can be used. Con-
nect the test equipment according to the instructions of the
manufacturer of the equipment.
1. The level of charge of the battery must be at least
75%. Perform the Specific Gravity Check in this sec-
tion.
2. Prepare the CAS10147 tester for the test.
A. Select the voltmeter range that will measure 1
- 18 V.
B. Make sure the load control knob is in the OFF
position.
C. Select the ammeter range that will measure 0
- 1000 A.
D. Move the volt lead switch to the NT position.
3. Connect the tester to the battery.
NOTE: Never apply a load for longer than 15 seconds. Af-
ter each 15 seconds, turn the load control knob to OFF for
at least one minute.
4. Apply a 15 A load to the battery for 15 seconds. Wait
at least three minutes before applying the load again.
5. Check and make a record of the temperature of the
electrolyte.
6. Find the correct load for this test in Specifications in
Section 4002.
NOTE: The correct load is half of the cold cranking am-
peres at -17 °C (1 °F).
7. Turn the load control knob until the ammeter indi-
cates the specified load. Keep the load for 15 sec-
onds and read the voltmeter. Turn the load control
knob to OFF.
8. Compare the test reading and the temperature of the
electrolyte to the chart below.
A. If the test result is equal to or more than the
voltage shown, the battery is in good condition.
B. If the test result is less than the voltage shown,
replace the battery.
47365539 08/07/2012
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Temperature of Minimum
electrolyte Voltage
21 °C (70 °F) or higher 9.6
16 °C (61 °F) 9.5
10 °C (50 °F) 9.4
4 °C (39 °F) 9.3
-1 °C (30 °F) 9.1
-7 °C (19 °F) 8.9
-12 °C (10 °F) 8.7
-18 °C (0 °F) 8.5
47365539 08/07/2012
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Battery - Charging
WARNING
Explosive gas!
battery.
W0005A
Before you charge the battery, check the level of the electrolyte.
It is difficult to give an exact charging rate because of the following variable conditions: (1) temperature of the elec-
trolyte, (2) level of charge, and (3) condition of the battery. Use the charging guide for the correct charging rate and
time.
Charging Guide For Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity Slow Charge Fast Charge
10 Hours at 5 A 2.5 Hours at 20 A
80 Minutes or Less
80 to 125 Minutes
7.5 Hours at 10 A 1.5 Hours at 50 A
20 Hours at 5 A 5 Hours at 20 A
125 to 170 Minutes
170 to 250 Minutes
* Initial rate for a standard taper charger.
NOTE: A maintenance free battery will have the words Maintenance Free on the decal on the top of the battery. If
the center part of the decal has been removed to get access to the battery caps, it is possible the words Maintenance
Free will have been removed from the decal.
Charging Guide For Batteries Other Than Maintenance Free Batteries

Recommended Rate* and Time for Fully Discharged Battery
Battery Capacity Slow Charge Fast Charge
80 Minutes or Less
80 to 125 Minutes
7.5 Hours at 10 A 1.5 Hours at 50 A
125 to 170 Minutes
170 to 250 Minutes
6 Hours at 40 A
Above 250 Minutes 24 Hours at 10 A
4 Hours at 60 A
* Initial rate for a standard taper charger.
The charging rate must be decreased if:

1. Too much gas causes the electrolyte to flow
from the cells.
2. The temperature of the electrolyte rises above
52 °C (126 °F).
NOTE: For the best charge, use the slow charging rates.
The battery is fully charged when, over a three hour period
at a low charging rate, no cell is giving too much gas, and
the specific gravity does not change.
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Preparing a dry charged battery for use

1. Remove the caps from the battery.
RCPH10TLB291AAF 1
2. Fill each cell to the top of the separators with elec-

trolyte. This will permit the volume of electrolyte to
increase when heated by charging the battery.
RCPH11TLB080AAL 2
3. Install the caps on the battery.

4. Connect a battery charger to the battery.
5. Charge the battery at 30 A until the specific gravity is
1.250 or more and the temperature of the electrolyte
is at least 15.5 °C (60 °F).
6. If necessary, fill each cell with electrolyte until the
electrolyte is just below split ring at the bottom of the
cell opening.
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Battery - Disconnect
WARNING
Explosive gas!
battery.
W0005A
WARNING
W0006A
1. Remove the battery cover hardware.
RCPH11TLB001AAM 1
RCPH11TLB002AAM 2
47365539 08/07/2012
55.302 / 10
3. Disconnect the negative battery cable from the neg-

ative battery terminal.
RCPH11TLB003AAM 3
Next operation:
Battery - Connect (55.302)
47365539 08/07/2012
55.302 / 11
Battery - Connect
WARNING
Explosive gas!
battery.
W0005A
WARNING
W0006A
1. Connect the negative battery cable to the negative

battery terminal.
RCPH11TLB003AAM 1
RCPH11TLB002AAM 2
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3. Install the battery cover hardware.
RCPH11TLB001AAM 3
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Battery connect/disconnect system Battery switch - Testing -

Master Disconnect Switch
580N T4, 580SN T4, 580SN WT T4, 590SN T4

Verify the battery connections are abrasion and damage. sion, abrasion and damage. Repair
tight and secure. Verify that the con- as required.
nections to the Master Disconnect
Switch are tight and secure. Check
the wiring and connections for corro-
sion, abrasion and damage. Verify
that the chassis ground frame con-
nections are secure and tight and
free of oil, paint, dirt, damage and
debris.
Turn the Master disconnect Switch The voltage should be approximately The voltage is less than 10 V. There
OFF. 12 V. is a problem in the battery circuit to
Check the Master Disconnect Switch. Ver-
Measure the voltage from Master ify that voltage across the battery ter-
Disconnect Switch terminal connec- minals. Repair as required.
tor X-479 to chassis ground.
Turn the Master disconnect Switch The voltage should be less than 1 V. The voltage is greater than 10 V.
OFF. There is a problem in the Master Dis-
Check connect Switch. Temporarily replace
Measure the voltage from Master the Master Disconnect Switch and
Disconnect Switch terminal connec- retest.
Turn the Master disconnect Switch The voltage should be approximately The voltage is less than 10 V, there
ON. 12 V. is a problem in the Master Discon-
Check nect Switch. Temporarily replace
Measure the voltage from Master the Master Disconnect Switch and
Disconnect Switch terminal connec- retest.
RCPH11TLB075FAL 1
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(1) Battery Disconnect Switch (3) Ground GND001

(2) Battery, 12 V (4) Optional Remote Jump Start
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Index
Battery - 302
Battery - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Battery - Connect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Battery - Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Battery - Inspect and clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Battery - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Battery - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Battery connect/disconnect system Battery switch - Testing - Master Disconnect Switch . . . . . . . . . . . . . . . . . . . . 14
580N T4, 580SN T4, 580SN WT T4, 590SN T4
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External lighting - 404
580N
580SN WT
580SN
590SN
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Contents
DIAGNOSTIC
External lighting
Testing Front Work Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Testing Flasher Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

580N T4, 580SN T4, 580SN WT T4, 590SN T4
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Electrical systems - External lighting
External lighting - Testing Front Work Light Switch

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Verify all wiring connections are tight abrasion and damage. sion, abrasion and damage. Repair
and secure. All connections should as required.
be free of corrosion, abrasion and
damage. Verify that the chassis
ground frame connections are se-
cure and tight and free of oil, paint,
dirt, damage and debris.
Turn the key switch OFF. The resistance should be less than The resistance is greater than 10 Ω
Check 10 Ω. there is a problem in the ground cir-
Measure the resistance between cuit to the switch. Repair or replace
Front Work Light Switch X-137 pin 9 as required.
to chassis ground.
Turn the key switch ON. The voltage should be between 12 V The voltage is less than 12 V. There
Check and 14.8 V. is a problem in the wiring to the
Measure the voltage from Front Front Work Light Switch. Check fuse
Work Light Switch connector X-137 F-006.
pin 2 to chassis ground.
Turn the key switch ON. Activate the The voltage should be between 12 V The voltage is less than 12 V. There
Front work Light Switch. and 14.8 V. is a problem in the Front Work Light
Check Switch. Replace the switch and
Measure the voltage from Front retest.
Work Light Switch connector X-137
pin 3 to chassis ground.
RCPH11TLB079FAL 1
(1) Switched Battery (5) Front Work Light E-006

(2) Fuse F-006 15 A (6) Front Lights Cab Ground GB-040
47365539 08/07/2012
55.404 / 3
Electrical systems - External lighting
(3) Front Work Light Switch S-007 (7) Front Work Light Backlight WB-028
(4) Front Work Light E-003 (8) Front Work Light Switch Lamp Ground
GB-034
External lighting - Testing Flasher Relay

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Verify all wiring connections to the abrasion and damage. sion, abrasion and damage. Repair
flasher relay are tight and secure. All as required.
connections should be free of corro-
sion, abrasion and damage. Verify
that the chassis ground frame con-
nections are secure and tight and
free of oil, paint, dirt, damage and
debris.
Check 10 Ω. Wiggle the harness during there is a problem in the ground cir-
Measure the resistance between measurement to reveal an intermit- cuit to the relay. Repair as required.
Flasher Relay connection X-010 pin tent condition.
4 to chassis ground.
Check 10 Ω. there is a problem in the wiring from
Measure the resistance between the Flasher Relay to the Turn Signal
Flasher Relay connection X-010 Indicator. Repair as required.
pin 3 to the Turn Signal Indicator
X-138 pin 2. Measure the resistance
between Flasher Relay connection
X-010 pin 6 to the Turn Signal Indica-
tor X-138 pin 3. Wiggle the harness
during measurement to reveal an
intermittent condition.
Turn the key switch ON. The voltage should be approximately The voltage is less than 10 V there
Check 12 V. is a problem in the battery supply to
Measure the voltage from Flasher the relay. Check fuse F-014. Repair
Relay connection X-010 pin 2 to as required.
chassis ground.
Turn the key switch ON. Fabricate a The hazard lights should light while The hazard lights did not light. Tem-
jumper wire 20 cm (8 in). the jumper is in place. porarily replace the Flasher Relay
Check and retest.
Use the jumper to short X-010 pin 2
to X-010 pin 1.
Turn the key switch ON. Each turn signal lamp should light A turn signal lamps did not light in-
Check independently of the other while the dependently or did not light while the
Use the jumper to short X-010 pin 2 jumper is installed. jumper is installed. Temporarily re-
to X-010 pin 5. Use the jumper to place the Flasher Relay and retest.
short X-010 pin 2 to X-010 pin 7.
47365539 08/07/2012
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Index

External lighting - Testing Flasher Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
External lighting - Testing Front Work Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N T4, 580SN T4, 580SN WT T4, 590SN T4
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Warning indicators, alarms, and instruments - 408
580N NA
580SN WT NA
580SN NA
590SN NA
47365539 08/07/2012
55.408 / 1
Contents
FUNCTIONAL DATA
Instrument cluster
Analog-Digital Instrument Cluster (ADIC) - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Instrument cluster
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Check - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
47365539 08/07/2012
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Electrical systems - Warning indicators, alarms, and instruments
Instrument cluster Analog-Digital Instrument Cluster (ADIC) -

Dynamic description
Advanced Instrument Cluster Overview

The obvious function of the Advanced Instrument Cluster (AIC) on the N Series Loader Backhoe is to display and
alert the operator of the current operating conditions. The warning lights (1) are located on the upper perimeter of
the AIC. The engine coolant and torque converter temperatures (2) are displayed on the gauges on the left side of
the inner area. The fuel level and the battery voltage (3) are displayed on gauges on the right side of the inner area.
The graphical tachometer (4) display of the engine speed is located in the upper center area of the AIC. In addition to
these indicator/warning lamps and gauges, the AIC display screen (5) at the lower center delivers text and graphical
information to the operator.
RCPH10TLB138AAF 1
In addition to vehicle condition instrumentation display, the Advanced Instrument Cluster (AIC) on the N Series Loader
Backhoes performs many machine control functions. The foot and hand throttle controls are directly connected to the
AIC. The AIC then processes these throttle signals and relays the speed command to the engine controller via the
CAN data bus wiring. The throttle control input from the hand throttle can be overridden by three other command
inputs to the AIC. The one touch idle control button at the top of the right hand backhoe pilot control lever toggles the
engine speed between the speed commanded by the hand throttle and low idle. A seat position switch also cancels
the hand throttle control when the seat is rotated between the backhoe and forward operating positions. The brake
light signal from both brake pedals cancel the hand throttle command when either or both brakes are depressed.
The AIC is also involved with the PowerLift feature. When activated and while operating the backhoe, the AIC com-
mands an increase in hydraulic system operating pressure, a decrease in hydraulic flow and a reduction in engine
speed when the PowerLift button is activated.
The display screen also allows the operator or technician to retrieve stored fault codes from the AIC to aid in diagnostic
troubleshooting. The display screen also provides much more detailed functional information to the operator.
The Advanced Instrument Cluster (AIC) is not involved in other machine functions. Engine cranking or starting is not
controlled in any way by the AIC. Starting and cranking are controlled by the engine control unit (ECU). The parking
brake function is not controlled by the AIC. An indicator light and LCD screen text are the only ways that the AIC is
involved with the parking brake. Glow plug operation is not controlled by the AIC other than the indicator light. The
glow plugs are controlled by the ECU.
47365539 08/07/2012
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Advanced Instrument Cluster Control Functions

In addition to vehicle condition instrumentation display, the Advanced Instrument Cluster (AIC) on the N Series Loader
Backhoes performs many control functions. The foot and hand throttle control sensors are directly connected to the
AIC. The AIC then processes these signals and relays the speed command to the engine controller via the CAN data
bus wiring.
A one touch idle control button is located on the top of the right hand backhoe control lever only on machines equipped
with pilot operated backhoe valve controls. While operating the backhoe, pressing this button once allows the operator
to reduce the engine speed to idle. Pressing the button again returns the engine speed back to the preset hand throttle
setting. This command is processed by the advanced instrument cluster (AIC).
The brake enabled idle feature returns the engine speed to idle when the hand throttle speed is above idle and either
or both brakes are pressed. Brake light switches located at each pedal send a brake apply signal to pin 28-7 of the
AIC as well as to the brake lights. This +12 volt signal causes the AIC to cancel hand throttle control any time that
either or both brakes are applied. Once a brake is pressed, the hand throttle control must be returned to the idle
position for the hand throttle to control the engine speed again. If the brake enabled idle feature has been turned off,
it returns to the ON setting by default at the next key cycle.
A seat position switch (SW-030), located on the seat pedestal, closes sending a 12 volt signal to the advanced in-
strument cluster (AIC) when the seat is facing forward, and is open when the seat is facing the backhoe operating
position. This switch cancels the hand throttle control when the seat is rotated. It also activates the hydraulic pump
torque control feature when the seat is forward. This feature limits the power available to the hydraulic pump to assure
that adequate engine power is available to the transmission to move the machine. A defective seat position switch,
(SW-030), or defective open circuit wiring, could cause the engine to overload while operating the loader. If the seat
position switch were to short to power while operating the backhoe, the backhoe function may appear slow or “weak”
to the operator.
PowerLift is a feature available on all of the Super N models. When PowerLift is turned on, the AIC activates three
machine controls. First, the AIC sends a 1450 RPM command to the engine controller. Secondly, the AIC activates
the hydraulic pump torque control solenoid. Thirdly, the AIC activates the PowerLift solenoid through the relay. When
the PowerLift solenoid is activated, the system operating pressure is increased to allow the backhoe to lift heavier
items for a short period of time. The PowerLift feature functions only while operating the backhoe.
To activate PowerLift, turn the switch (S-012) located on the right hand console to the on position to send a 12 volt
signal to the AIC. The Powerlift feature will only activate when the seat is facing the backhoe operating position and
the seat position switch (SW-030) is open. The AIC then commands the engine controller to reduce the engine speed
to 1450 RPM. The AIC also sends a 12 volt signal to the PowerLift relay control coil terminal 85. Once closed, the
PowerLift relay then sends a 12 volt signal to the PowerLift solenoid and also to the torque control solenoid through
the torque control diode. The engine speed will reduce, the hydraulic flow will reduce and the pressure will increase
to allow the backhoe to handle heavier objects.
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Break Enabled Idle Control Wiring
RAPH12TLB0173EA 2
PowerLift Control Feature Schematic
RAPH12TLB0174EA 3
47365539 08/07/2012
55.408 / 5
Advanced Instrument Cluster Adjustments

In addition to the indicator/warning lamps, the Advanced
Instrument Cluster (AIC) displays information on the LCD
display screen. The menu screens can also be used to
program machine functionality and perform diagnostics
and troubleshooting.
RCPH10TLB138AAF 4
1. Use the two rocker switches on the side console to
move through the menu screens.
Escape (1) - Return to the previous top menu or escape
back to the main screen.
Enter (2) - Select specific display screens or store screen
defined configuration settings to memory.
Up arrow (3) - Move backward through the menu
screens.
Down arrow (4) - Move forward through the menu
screens.
To perform AIC adjustments follow these steps:
A. Press Enter (2) to access the menu screens.
B. Press the up arrow (3) or the down arrow (4) to

navigate through the menu screens.
C. When the desired screen displays, press ENTER.

The adjustable setting flashes.
D. Press the up arrow or the down arrow to adjust RCPH10TLB140AAF 5

the setting.
E. Press ENTER to save the selection and return to

the menu.
F. Use the arrows to navigate to a different menu

screen. Use steps B. through E. to make additional
changes or press Escape (1) until you return to the
main screen (engine hour meter).
47365539 08/07/2012
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2. Main (engine hour) display screen:
A. On startup, shows the main screen graphic along

with the machine hours.
B. Once the navigation is complete press Escape

(1) until you return to the main screen (engine hour
meter).
RCPH10TLB194AAF 6
3. Transmission Shuttle Shift Aggressiveness
Adjustment - FNR sensitivity screen:
A. Shift aggressiveness screen displays and lets

you specify the sensitivity/aggressiveness setting
for Forward/Neutral/Reverse shift.
NOTE: Machines with Powershift S-type or Power-

shift H-type transmissions only.
RCIL10TLB035AAF 7
4. Display dimmer/brightness screen:
A. Displays and lets you specify the incremental

value for the screen brightness.
B. Four bars are maximum screen brightness.
RCPH10TLB196AAF 8
47365539 08/07/2012
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5. Service interval adjustment screen:
A. Lets you specify what service interval, when

reached, displays on the screen at key up.
B. Heavy service hours: 500 to 1000 hours at 100

hour increments.
C. Light service hours: 50 to 500 at 50 hour incre-

ments.
RCPH10TLB198AAF 9
NOTE: The screen displays '---' if no service interval
is specified.
6. Engine pre-heat presence screen:
A. Displays and lets you specify activation of the

engine preheat system.
B. This graphic indicates that the engine is equipped

with the pre-heat system.
NOTE: If the machine is not equipped with a grid

heater a diagonal line appears on the screen
graphic. RCPH10TLB200AAF 10
7. Engine speed display screen:
A. This feature is available only on machines with

electronically controlled high pressure common rail
(HPCR) fuel injection engine.
B. Lets you access the Idle Increment screen to ad-

just the cold start idle and maximum throttle values
for special operating conditions.
C. Cold start idle – Sets the minimum engine speed

(up to 1500 RPM), that the engine idles at while cold.
RCPH10TLB201AAF 11
D. Maximum throttle – Sets the maximum engine

speed during operation. The engine will not exceed
this speed.
47365539 08/07/2012
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8. Brake enabled idle selection screen:

Brake Enable Idle ON
B. Brake enabled idle returns engine speed to idle

when the hand throttle speed is above idle and ei-
ther or both brakes are pressed. Once the brake
enabled idle feature has been triggered, the hand
throttle control must be returned to the idle posi-
tion for the hand throttle to control the engine speed
again.
C. When the AIC feature is turned off and/or when RCPH10TLB204AAF 12

the OFF graphic display is shown, the brakes will Brake Enable Idle OFF
not cancel the hand throttle control.
D. NOTE: The brake enabled idle feature returns to

the ON setting by default at the next key cycle.
E. The Brake Enabled Idle Selection screen lets the

operator turn off the brake enabled idle feature so
that pressing the brake pedal will not cancel the
hand throttle control.
RCPH10TLB205AAF 13
F. The hand throttle control is cancelled whenever
the seat is turned around. Return the hand throttle
dial to the idle position to restore (capture) the hand
throttle.
47365539 08/07/2012
55.408 / 9
9. Throttle sensitivity adjust screen:

B. Displays and lets the operator specify the sen-

sitivity setting for the electronic foot throttle, where
1 is least aggressive and 3 is most aggressive.
Reducing the sensitivity minimizes engine surging
caused by rapid pedal movement while operating
over rough terrain. Operators can change the elec-
tronic throttle sensitivity for working conditions or RCPH10TLB195AAF 14
personal preference.
10. Machine hardware display screen:
A. Displays the advanced instrument cluster (AIC)

part number and other detailed information.
RCPH10TLB422AAF 15
11. Machine software Display screen:
A. Displays the advanced instrument cluster (AIC)

software part number and other detailed informa-
tion.
RCPH10TLB421AAF 16
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Diesel Particulate Filter (DPF) Emission System Controls

The advanced instrument cluster (AIC) displays Tier 4 engine diesel particulate filter (DPF) emission control system
regeneration information. The AIC can inhibit the automatic regeneration of the DPF system. The AIC can also be
used to command the forced regeneration of the DPF system when conditions require this process. Refer to Par-
ticulate filters - Dynamic description (10.501) theory of operation section of this manual for additional information
about this system.
DPF Auto Regeneration

The DPF system will automatically elevate the operating temperature high enough to burn exhaust particulate matter
(PM), or regenerate, when commanded by the engine controller.
DPF Auto Regeneration

1. Operator is notified of the beginning of Auto
Regeneration by a single audible beep and the DPF
regeneration ON symbol appears on the AIC display
screen. The DPF regeneration process begins and the
display will alternate between the DPF ON symbol and
the hour meter, approximately 10 times.
RCPH11TLB006AAD 17
2. After the regeneration process is complete a single
audible beep and the DPF regeneration OFF symbol
will appear on the AIC display screen. The display will
alternate between the DPF OFF symbol and the hour
meter, approximately 10 times.
RCPH11TLB005AAD 18
Loader Backhoe DPF Auto Regeneration inhibit
The engine DPF system regeneration process causes elevated exhaust system temperatures which might not be ac-
ceptable under all conditions. The operator may choose to delay the auto regeneration process. However, continuing
to delay the auto regeneration process will eventually require a forced regeneration.
NOTE: The regeneration inhibit feature returns to the enable setting by default at the next key cycle.
NOTE: The operator may choose to delay the auto regeneration process. However, continuing to delay the auto
regeneration process will eventually require a forced regeneration.
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DPF Auto Regeneration Inhibit

1. Disable the regeneration inhibit feature:
A. Press Enter (2) to access the menu screens.
B. Press the up arrow (3) or the down arrow (4) to

navigate through the menu screens.
RCPH10TLB140AAF 19
2. When the regeneration inhibit Selection screen
displays, press Enter. The menu screen flashes.
RCPH11TLB008AAD 20
3. Press ENTER to disable the regeneration inhibit
process. The display screen changes to indicate the
feature is disabled.
NOTE: The regeneration inhibit disabled image will

reappear on a consistent basis with an audible alert
until the operator enables the feature or turns the
machine off.
RCPH11TLB007AAD 21
4. Use the arrows to navigate to a different menu screen
or press Escape (1) until you return the main screen
(engine hour meter).
RCPH10TLB140AAF 22
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DPF Forced Regeneration
Engine DPF system forced regeneration requires an operator command. A differential pressure sensor monitors the
particulate matter (PM) buildup in the DPF. If the automatic regeneration process is interrupted or does not adequately
remove the particulate matter (PM), the diesel particulate filter (DPF) will become obstructed. When the differential
pressure sensor senses this obstruction, the instrument cluster will display a warning and activate an audible alarm
to instruct the operator to command a forced regeneration. If the operator does not force the regeneration as indi-
cated, the engine controller limits the engine torque. At the first level of restriction, the engine torque will reduce to
approximately 50%. If the restriction continues to build, the engine torque will reduce to approximately 33%.
To activate forced regeneration, specific conditions must be met. These are, throttle at minimum position, vehicle
speed at zero, if speed is monitored, otherwise park brake engaged, PTO not engaged and hydraulics not active. If
one of the conditions have not been met, the instrument cluster will display the problem. During forced regeneration,
the machine must remain at idle and cannot be used. Cyclical loads can cause the forced regeneration to stop so
features such as Air Conditioning must be turned off prior to forcing regeneration. Manual or forced regeneration can
be suspended by operating the accelerator or pressing the activation switch again. Care should be taken to normally
allow the forced regeneration process to complete once it has been initiated.
The operator may NOT continue to operate the machine normally during the forced regeneration process.
During the forced regeneration process an increase in engine noise level may be observed.
During the forced regeneration process a burning or “hot” odor may be present.
The forced regeneration process will last approximately 20 minutes depending on the ash level in the DPF.
If the forced generation process is not allowed the machine will begin to de-rate. Damage or shortened DPF life may
occur if the forced regeneration is ignored for an extended period of time.
WARNING
Fire hazard!
During the Diesel Particulate Filter (DPF) forced regeneration process the exhaust stack and fixed
hood area becomes extremely hot. Park the machine outside and away from combustible or highly
flammable material.
W1165B
CAUTION
Burn hazard!
During the Diesel Particulate Filter (DPF) regeneration process the exhaust stack and fixed hood area
becomes extremely hot. Allow area to cool before servicing or working near the exhaust system com-
ponents.
Failure to comply could result in minor or moderate injury.
C0102B
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Forced Regeneration
1. When a forced regeneration is required, the operator
will be notified with one of the following:
A. Extended audible alert, amber LED

lamp and the DPF regeneration PARK symbol will
appear on the display screen. Indicating a high
B. Constant audible alert, red LED lamp

and the DPF regeneration PARK symbol will appear RCPH11TLB004AAD 23
on the display screen. Indicating an extremely high
2. Calmly find a location out of the way on the job site
and clear away from any combustible material. Perform
the following:
A. Put the machine in Neutral.
B. Engage parking brake.
C. Put both the hand and foot throttles in their idle

position.
D. Wait for the DPF regeneration START symbol to

appear on the display.
RCPH11TLB003AAD 24
NOTE: Changing any of the above conditions dur-

ing the forced regeneration process will cause the
process to FAIL.
3. Press Enter
RCPH10TLB140AAF 25
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4. DPF regeneration WAIT symbol appears. The system

is validating machine readiness and all actions in step 2
have been completed.
RCPH11TLB002AAD 26
5. One of the following will occur.
A. DPF regeneration ON symbol appears indicating

the regeneration process has started, allow approx-
imately 20 minutes to complete
RCPH11TLB006AAD 27
B. DPF regeneration FAIL symbol appears indicat-

ing the machine is not ready. Repeat step 2.
NOTE: If the DPF regeneration continues to FAIL

contact your authorized dealer for service.
RCPH11TLB010AAD 28
6. DPF regeneration OFF symbol appears indicating the
forced regeneration process is complete. Machine is
ready for operation.
RCPH11TLB005AAD 29
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Fault Code Retrieval

The advanced instrument cluster (AIC) and other machine electronic controllers can activate a fault code when a
problem arises. When a fault code has been logged, the amber diamond with the exclamation mark LED lamp (B)
is activated on the left side of the cluster. The AIC can display fault codes from other electronic controllers on the
machine which communicate between each other via the CAN data bus.
1. The advanced instrument cluster (AIC) display screen

(A) allows the operator or technician to retrieve stored
fault codes from the AIC (arrow) and insert enlargement
(B) to aid in diagnostic troubleshooting.
RAPH12TLB0177AA 30
2. To retrieve stored fault codes, use the two rocker
switches on the side console to move through the menu
screens.
A. Escape (1) - Return to the previous top menu or

escape back to the main screen.
B. Enter (2) - Select specific display screens or store

screen defined configuration settings to memory.
C. Up arrow (3) - Move backward through the menu

screens.
RCPH10TLB140AAF 31
D. Down arrow (4) - Move forward through the menu

screens.
3. To retrieve stored AIC fault codes (from step 1) follow
these steps:
A. Press Enter (2) (shown in step 2) once to access

the menu screens.
B. Press the up arrow (3) or the down arrow (4)

(shown in step 2) to navigate through the menu
screens until the stored fault code screen (B) dis-
plays.
RAPH12TLB0178AA 32
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4. When the stored fault code screen displays, press

Enter. The first fault code information will display. The
fault code information is:
A. Fault code sequence number.
B. Total number of faults stored.
C. Fault code number.
D. Number of occurrences of this fault.
RAPH12TLB0179AA 33
E. The hour reading on the machine at the last oc-
currence of this fault.
5. Press the up arrow (3) or the down arrow (4) to
navigate through any additional stored faults.
6. Press Escape (1) until you return to the main screen

(engine hour meter).
RCPH10TLB140AAF 34
Advanced Instrument Cluster Diagnostic Tests

The Advanced Instrument Cluster (AIC) can also be used as a diagnostic tool. The AIC indicator/warning lamps and
gauges can be tested by initiating the Self Test mode. Carefully monitor each of the Self Test steps to assure the
cluster is functioning correctly. The Self Test feature validates all of the AIC instrumentation display functions. If
required, repeat the Self Test activation to assure proper AIC function. After the Self Test completes, the AIC enters
the Test Mode. When the Self Test mode is activated, the AIC will display the following functions sequentially:
1. All indicator/warning lights turn on at full intensity for 7. Voltmeter gauge sweep to second red/green border.
2 sec.
2. Wait 2 sec. 8. All gauges park.
3. All backlights light to full intensity for 2 sec. 9. LCD test: LCD display shows checkerboard pattern.
4. Wait 2 sec. 10. Sound the alarm for 2 sec.
5. All gauges sweep to full angle for 2 sec. 11. Begin the AIC test mode.
6. All gauges sweep to red/green border for 2 sec.
If a new AIC is installed, it must be configured using the Electronic Service Tool (EST) for the following parameters:
model, engine type, transmission type, and hydraulic pump type. This must be performed before placing the unit
into service, or fault codes and limited operation will result. The Electronic Service Tool (EST) can also be used to
troubleshoot systems associated with the AIC.
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1. After the AIC cycles through the Self Test steps, the
AIC Test Mode begins with the foot throttle data. Use the
up/down arrow to step through the test data. The Test
Mode can validate the:
A. Foot throttle supplied voltage.
B. Foot throttle control voltage
C. Hand throttle supplied voltage
D. Hand throttle control voltage
E. Foot throttle signal percentage
F. Hand throttle signal percentage
G. Requested engine RPM
H. Fuel level in percentage
I. Fuel tank selection
J. System voltage
K. Transmission oil temp degrees C - 73 °C is the

minimum value displayed
L. Brake enabled idle ON/OFF
M. Actual engine RPM
N. Engine coolant temp degrees C
O. Engine intake air temp degrees C

RAPH12TLB0180CA 35
P. Fuel temp degrees C
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Instrument cluster - Visual inspection

The backlighting for the instrument cluster is illuminated only when the driving lamp switch is in the ON position.
When the ignition (key) switch is in the ON position and the engine is not running the Air Filter Restriction, Hydraulic
Oil Filter Restriction, Alternator, and Low Engine Oil Pressure Warning Lamps are illuminated.
When the ignition (key) switch is first turned to the ON position the Air Filter Restriction Warning Lamp, Hydraulic Oil
Filter Restriction Warning Lamp, Parking Brake Indicator Lamp and the Air Conditioning System Pressure Indicator
Lamp (if equipped), will illuminate for 3 seconds for a bulb self test.
Warning and indicator lamp status at power on

1. Turn the ignition (key) switch to the ON position.
2. All LED’s (Light Emitting Diodes) will illuminate for 2
- 3 seconds.
3. The warning alarm will sound for 1 second.
4. If an active fault is found, the associated visualization
will occur with the display, LEDs, and alarm. Refer
to Instrument cluster Digital instrument cluster -
Special instruction (55.408) for more details.
5. If no active fault is found, the display will be green in
color showing the current machine hour meter value.
Self test procedure

1. Simultaneously turn the ignition (key) switch ON and
press any display function switch (up arrow, down
arrow, enter, or escape). However, simultaneously
pressing the down arrow and escape switches will
initiate the system configuration mode.
2. The following occurs during the self test. Watch
for burnt out lamps and incorrect movement of the
gauges:
A. Lamps turn on at full intensity.
B. Lamps turn off after 2 seconds.
C. Wait 2 seconds.
D. Instrument backlighting turns on at full intensity.
E. Instrument backlighting turns off after 2 sec-
onds.
F. Wait 2 seconds.
G. All gauges sweep to the maximum angle.
H. Wait 2 seconds, applicable gauges sweep to
the maximum red/green border.
I. Wait 2 seconds, applicable gauges sweep to
the red/green border.
J. Wait 2 seconds, gauges release to their rest-
ing position and the display test (checkered
screen) is initiated.
K. After completion of the display test, an audible
alarm occurs for 2 seconds.
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3. The self test is now complete and the display will

default into configuration mode. Proceed to step of
the Configuration mode procedure or turn the ignition
(key) switch to the OFF position.
NOTE: When defective gauges are found refer to Instru-
ment cluster - Check (55.408) for more details.
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Instrument cluster - Check - Instrument cluster

The backlighting for the instrument cluster is illuminated only when the driving lamp switch is in the ON position.
When the ignition (key) switch is in the ON position and the engine is not running the Air Filter Restriction, Hydraulic
Oil Filter Restriction, Alternator, and Low Engine Oil Pressure Warning Lamps are illuminated.
When the ignition (key) switch is first turned to the ON position the Air Filter Restriction Warning Lamp, Hydraulic Oil
Filter Restriction Warning Lamp, Parking Brake Indicator Lamp and the Air Conditioning System Pressure Indicator
Lamp (if equipped), will illuminate for 3 seconds for a bulb self test.
Low engine oil pressure warning lamp

The warning lamp for low engine oil pressure will il-
luminate with the key switch in the ON position and
the engine NOT running. If the warning lamp does
not illuminate:
1. Check for a defective lamp.
2. Check for corrosion or bad connections at the
socket in the instrument cluster and at the
switch for engine oil pressure.
3. Check the wire between the oil pressure switch
and the instrument cluster.
4. See Instrument cluster - Check (55.408) in
this Manual for complete troubleshooting pro-
cedure for the instrument cluster.
Alternator warning lamp

The warning lamp for the alternator will illuminate
with the key switch in the ON position and the en-
gine NOT running. If the warning lamp does not illu-
minate:
1. Check for a defective lamp.
2. Check for corrosion or bad connections at the
socket in the instrument cluster and at the al-
ternator.
3. Check the wire between the alternator and the
instrument cluster.
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Hydraulic oil filter restriction

1. The Hydraulic oil filter restriction warning lamp will
illuminate with the key switch in the ON position and
the engine NOT running. If the warning lamp does
not illuminate:
A. Check for a defective lamp.
B. Check for corrosion or bad connections at the
socket in the instrument cluster and at the Hy-
draulic oil filter restriction switch.
C. Check the wire between the Hydraulic oil filter
restriction switch and the instrument cluster.
D. Check for a damaged wire between the instru-
ment cluster and the IGN terminal of the key
switch.
E. Defective switch.
2. When the warning lamp for the Hydraulic oil filter re-
striction is illuminated while the engine is running, the
cause can be:
1. Dirty filter.
2. Defective switch for the warning lamp.
3. Short circuit in the wire between the switch and
the warning lamp.
4. Cold hydraulic oil will also cause the switch to
activate.
Air filter restriction

1. The Air filter restriction warning lamp will illuminate
with the key switch in the ON position and the en-
gine NOT running. If the warning lamp does not illu-
minate:
A. Check for a defective lamp.
B. Check for corrosion or bad connections at the
socket in the instrument cluster and at the Hy-
draulic Oil Filter Restriction switch.
C. Check the wire between the Air filter restriction
switch and the instrument cluster.
D. Check for a damaged wire between the instru-
ment cluster and the IGN terminal of the key
switch.
E. Defective switch.
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2. When the warning lamp for the Hydraulic oil filter re-
striction is illuminated while the engine is running, the
cause can be:
A. Dirty filter.
B. Defective switch for the warning lamp.
C. Short circuit in the wire between the switch and
the warning lamp.
D. See Instrument cluster - Check (55.408) in
Parking brake indicator

1. The parking brake indicator will illuminate when the
parking brake is applied.
2. See Instrument cluster - Check (55.408) in this
Manual for the procedure to check the Parking brake
indicator lamp.
Driving lamps indicator

1. The Driving lamps indicator will illuminate when the
driving lamp switch is in the ON position.
Manual for the procedure to check the Driving lamps
indicator.
Low fuel level indicator

1. The Low fuel level indicator illuminates when the ma-
chine's fuel level is low.
Manual for the procedure to check the Fuel Level
Sender.
Air conditioning system pressure indicator (if equipped)

1. The Air conditioning system pressure indicator illu-
minates when the air conditioner has stopped due to
refrigerant pressures that are too high.
Manual for the procedure to check the Air condition-
ing system high and or low pressure switch.
Grid heater indicator (if equipped)

1. The Grid heater indicator illuminates when the en-
gine temperature is below 0 °C (32 °F) and the grid
heater is functioning.
Manual for the procedure to check the Grid Heater
and the Grid Heater Indicator Lamp.
Configuration mode
NOTE: This procedure can also be used for diagnostic pur-
poses.
47365539 08/07/2012
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1. Simultaneously press and hold the down arrow and

the escape buttons. Turn the ignition (key) switch to
the ON position.
2. The display will show the configuration mode.
3. To reset the instrument cluster, turn the ignition (key)
switch to the Off position.
4. A total of nine settings may be changed. Press the up
or down arrow to scroll through the settings. Press
the enter key to select the desired setting.
• Transmission oil temperature and
Vehicle Voltage
• Fuel level % and Fuel Tank #
• Requested RPM
• Foot Throttle % and Hand Throttle %
• Hand Throttle Voltage Output and
Hand Throttle Signal Voltage Out
• Foot Throttle Voltage Output and
Foot Throttle Signal Voltage Out
• Oil Temperature and Fuel Temperature
• Coolant Temperature and Air Temperature
• Brake Enable ON/OFF and RPM (580N only)
5. Press the up or down arrows to change the current
setting.
6. Press the enter key to save any changes.
7. Press the escape key repeatedly until the main
screen (hourmeter) is displayed.
Software version retrieval

1. Turn the ignition (key) switch to the ON position.
2. Press the enter key.
3. Press the up arrow 3 times.
4. The software version will be displayed.
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Instrument cluster - Check

The Engine coolant temperature, Oil temperature, Voltmeter, Fuel level gauges, and the Tachometer are all serviced
as one unit. If one gauge or the tachometer is defective, they must all be replaced as one unit in the instrument panel
cluster.
Prior operation:
Instrument cluster - Visual inspection (55.408)
Engine coolant, Oil temperature or Fuel level gauges

1. If the gauge does not work correctly:
A. Disconnect the wire from the sender.
B. Turn the ignition (key) switch to the ON posi-
tion.
C. Hold the wire against the frame or the engine
until you have a good ground connection.
D. Have another person look at the gauge. If you
are checking the engine coolant or the oil tem-
perature gauge, the needle must move all the
way to the right (red zone). If you are checking
the fuel level gauge, the needle must move all
the way to the left (empty position).
E. If the needle moved, the sender is bad and
must be replaced. If the needle did not move,
the gauge is bad or there is an open circuit in
the wires between the sender and the gauge.
F. Install the wire on the sender.
G. Refer to Instrument cluster - Remove
(55.408) for removal procedure.
H. Refer to Wire harnesses - Electrical
schematic frame 11 (55.100) for the location
of the terminal in the connector on the wiring
harness. Connect one lead of an ohmmeter
to the terminal in the connector. Connect the
other lead of the ohmmeter to a good ground
connection
I. If the ohmmeter did not indicate continuity,
there is a short circuit in the wires between the
connector and the sender. Repair or replace
the wires. If the ohmmeter indicated continuity,
the wires are good and the gauge assembly
must be replaced.
2. If the gauge only works part of the time, the cause
could be one of the following:
A. A bad connection at the sender.
B. A bad connection at the instrument panel.
C. A bad connection in the connectors in the
wiring harness.
D. A short circuit or an open circuit in the wires
between the instrument panel and the sender.
E. Defective sender.
F. Defective gauge.
See Instrument cluster - Check (55.408) for complete
troubleshooting procedure for the instrument cluster.
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Voltage gauge
1. Connect the positive lead of a test voltmeter to the
positive post of the batteries. Connect the negative
lead of the test voltmeter to the negative post of the
batteries. If the machine has two batteries, make
sure the leads are connected to the same battery.
2. Start and run the engine at 1500 RPM.
3. Read the test voltmeter, the reading should be
greater than 12 V.
4. Check the voltage gauge on the machine:
• If the needle on the gauge is within the green
field it is working properly.
• If the needle on the gauge is not in the red field
replace the gauge assembly.
5. See Instrument cluster - Check (55.408)for com-
plete troubleshooting procedure for the instrument
cluster.
Tachometer gauge
1. The tachometer shows the engine speed in revolu-
tions per minute (rpm). The engine rpm signal comes
from the alternator “W” terminal. If the tachometer is
not working the cause could be the operation of the
alternator.
Check the operation of the alternator. Refer to In-
strument cluster - Check (55.408)
• If the alternator is not working correctly repair
or replace the alternator. Refer to NEED IU
REFERENCE for servicing the alternator.
• If the alternator is working correctly,
A. Remove the instrument cluster from the
console and disconnect the electrical
connector from the console.
B. Connect one lead of an ohmmeter to ter-
minal T19 in the connector and connect
the other lead of the ohmmeter to a good
ground.
C. The ohmmeter should indicate continuity,
however if the ohmmeter does not indi-
cate continuity, check the wire between
the connector and the alternator. If nec-
essary repair or replace the wire.
2. If the tachometer still does not operate, check the
instrument cluster. Refer to Instrument cluster -
Visual inspection (55.408) for the procedure to
check the instrument cluster. Replace the gauge and
tachometer assembly as required refer to Instru-
ment cluster - Disassemble (55.408) for details.
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Instrument cluster - Remove

1. Remove the two screws from the front of the instru-
ment cluster panel. Lift the panel off the side console.
RCPH10TLB339AAF 1
2. On a clean nonabrasive surface, place the instru-

ment panel face down.
Next operation:
Instrument cluster - Disassemble (55.408)
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Instrument cluster - Disassemble

NOTICE: Adhere to the Electromagnetic Compatibility (EMC) standards when working with electronic components.
At the very minimum be sure you are properly grounded, the proper tools are used and electrical circuit boards are
held by the edges.
Prior operation:
Instrument cluster - Remove (55.408)
1. Remove the two screws that secure the rear cover to

the frame.
2. Remove the rear cover (1) from the frame (2).
3. When replacing a defective bulb, turn the bulb/socket
assembly counter-clockwise and remove. Replace
assembly as required.
NOTE: The bulb and socket assembly are serviced as one
unit. Do not replace individual components.
4. From the back of the circuit board, remove the 15
nuts and washers that secure the four gauges and
tachometer to the circuit board.
5. From the outside edges of the circuit board, remove
the 12 screws that fasten the circuit board to the
frame.
6. Remove the circuit board with dot matrix display from
the frame.
NOTE: The circuit board with dot matrix display are ser-
viced as one unit. Do not replace individual components.
The circuit board typically does not cause problems but you
may test the continuity of the unit for faults. With an Ohm
meter, test each strip on the circuit board for continuity. Re-
place the circuit board if continuity is not achieved on any
of the circuit board strips.
7. Remove the two screws that secure the front trim to
the frame. Remove the trim.
8. Remove the eight screws that fasten the lens to the
frame. Remove the lens.
9. Remove the five screws that fasten the overlay,
gauges, tachometer, and light pipe to the frame as
one unit. Remove the assembly and replace as
required.
NOTE: The gauges, tachometer, overlay, and light pipe are
serviced as one unit. Do not replace as individual compo-
nents.
10. Inspect the O-ring on the rear cover. Replace as
required.
Next operation:
Instrument cluster - Assemble (55.408)
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Instrument cluster - Assemble

Prior operation:
Instrument cluster - Disassemble (55.408)
1. When required, insert new bulb/socket assemblies

into the circuit board and turn clockwise to secure in
place.
2. Position the overlay, gauges, tachometer, and light
pipe as one unit into the frame. Secure the assembly
in place with five screws.
3. Secure the lens to the frame with 8 screws. Tighten
to a torque of 1.1 N·m (10 lb in).
4. Position the front trim over the lens and secure it in
place with two screws.
5. Align the circuit board with dot matrix display into
the frame. Ensure the screw posts from the gauges
and tachometer are exposed on the back side of the
circuit board.
6. Secure the outside edges of the circuit board to the
frame with 12 screws.
7. Secure the gauges and tachometer to the circuit
board with nuts and washers.
8. Place the O-ring over the rear cover.
9. Place the rear cover over the back of the frame and
secure it in place with two screws.
Next operation:
Instrument cluster - Install (55.408)
47365539 08/07/2012
55.408 / 29
Instrument cluster - Install

Prior operation:
Instrument cluster - Remove (55.408)
1. Align the back pins on the instrument cluster panel

with the connector in the opening on the right-hand
side console. Gently and evenly push the assembly
into the opening.
2. Secure the assembly in place with two screws.
RCPH10TLB339AAF 1
47365539 08/07/2012
55.408 / 30
Index

Instrument cluster - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Instrument cluster - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Instrument cluster - Check - Instrument cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Instrument cluster - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Instrument cluster - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Instrument cluster - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Instrument cluster - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Instrument cluster Analog-Digital Instrument Cluster (ADIC) - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . 3
47365539 08/07/2012
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Cab/Platform harnesses and connectors - 510
580N
580SN WT
580SN
590SN
47365539 08/07/2012
55.510 / 1
Contents
DIAGNOSTIC
Auxiliary power plugs and sockets

Testing Power Point 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Testing Power Point 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

580N T4, 580SN T4, 580SN WT T4, 590SN T4
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Electrical systems - Cab/Platform harnesses and connectors
Auxiliary power plugs and sockets - Testing Power Point 1

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Turn the key switch OFF. The resistance should be less than The resistance is greater than 10
Check 10 Ω. Ω, there is a problem in the chassis
Measure the resistance from Power ground connection to the Power Out-
Outlet 1 connector X-181 pin B to let 1. Verify the wiring is secure and
chassis ground. free of corrosion, abrasion and incor-
Turn the key switch ON. The voltage should be approximately The voltage is less than 10 volts,
Check 12 volts. there is a problem in the 12 supply
Measure the voltage from Power Action to the Power Outlet. Check Fuse
Outlet connector X-181 pin A to ter- Temporarily replace the Power Out- F-016. Repair as required.
minal Power Outlet connector X-181 let and retest.
pin B.
RCPH11TLB076FAL 1
(1) Switched Battery, 12 V (4) Power Point 1 Ground connection

(2) Power Point 1 (5) Power Point 2 Ground connection
(3) Power Point 2 (6) Fuse F-016 30 A
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Electrical systems - Cab/Platform harnesses and connectors
Auxiliary power plugs and sockets - Testing Power Point 2

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Turn the key switch OFF. The resistance should be less than The resistance is greater than 10
Check 10 Ω. Ω, there is a problem in the chassis
Measure the resistance from Power ground connection to the Power Out-
Outlet 1 connector X-182 pin B to let 1. Verify the wiring is secure and
chassis ground. free of corrosion, abrasion and incor-
Turn the key switch ON. The voltage should be approximately The voltage is less than 10 volts,
Check 12 volts. there is a problem in the 12 supply
Measure the voltage from Power Action to the Power Outlet. Check Fuse
Outlet connector X-182 pin A to ter- Temporarily replace the Power Out- F-016. Repair as required.
minal Power Outlet connector X-182 let and retest.
pin B.
RCPH11TLB076FAL 1
(1) Switched Battery, 12 V (4) Power Point 1 Ground connection

(2) Power Point 1 (5) Power Point 2 Ground connection
(3) Power Point 2 (6) Fuse F-016 30 A
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Index

Auxiliary power plugs and sockets - Testing Power Point 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Auxiliary power plugs and sockets - Testing Power Point 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
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Cab engine controls - 525
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Throttle control
Exploded view - Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Throttle control
Adjust - Throttle linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adjust - Throttle lever adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
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Electrical systems - Cab engine controls
Throttle control - Exploded view - Throttle linkage
RCPH10TLB044GAL 1
1. Ball joint 6. Lever - hand throttle 11. Injection pump lever

2. Throttle lever 7. Cable 12. Cable jam nuts
3. Clevis 8. Cable jam nuts 13. Cable
4. Cross shaft 9. Lever - foot throttle 14. Clevis
5. Throttle pedal 10. Jam nut 15. Lock nut
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Throttle control - Adjust - Throttle linkage adjustment

1. Disconnect the ball joint (1) from the lever on the fuel
injection pump. See the illustration Throttle control
- Exploded view - Throttle linkage (55.525).
2. Use a photo tachometer or other tachometer of equal
accuracy to check the engine speeds. If the engine
speeds are not equal to the specifications in this sec-
tion, adjust the engine speeds as required. See Spe-
cial Tools in this section.
NOTE: Adjustment of high idle must be done by an authorized Case dealer.

3. Push the throttle lever (2) forward until the lever (9)
on the cross shaft (4) touches the fire wall. If the
lever (9) does not touch the fire wall, adjust the cable
clevis (14) until the lever (9) touches the fire wall.
4. Connect the ball joint (1) to the lever on the fuel in-
jection pump.
5. Move the throttle lever (2) to the high idle position.
The ball joint (1) must obtain 1 mm (0.039 in) over-
ride at the injection pump lever (11) on the fuel injec-
tion pump.
6. To obtain the required override, adjust the throttle
cable jam nuts (8) at the engine.
7. Check to see that the high and low idle engine
speeds are as specified.
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Throttle control - Adjust - Throttle lever adjustment

Move the throttle lever (2) to the high idle position and then
to the low idle position. The throttle lever (2) must move
smoothly and hold the setting for the throttle lever (2) when
the throttle lever (2) is released. If the throttle lever (2)
does not move smoothly or hold the setting after the throttle
lever (2) has been released, the throttle lever (2) must be
adjusted. The inner nut (15) must be torqued to 5.6 - 6.2
N·m (50 - 55 lb in) then torque the outer jam nut (10) to 3.3
- 5.7 N·m (29 - 50 lb in).
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Index

Throttle control - Adjust - Throttle lever adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Throttle control - Adjust - Throttle linkage adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Throttle control - Exploded view - Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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FAULT CODES - DTC
580N
580SN WT
580SN
590SN
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Contents
FAULT CODES - DTC
DIAGNOSTIC
0000-Retrieving fault codes, Backhoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1001-Engine Air Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1002-Engine coolant temperature too high, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1003-Air conditioning pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1004-Hydraulic filter blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1009-Transmission oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1010-Foot throttle signal out of range, IVS not changing state in 300 ms . . . . . . . . . . . . . . . . . . . . . . . . . . 38
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1011-Foot throttle signal out of range, throttle above 95% of input for 5 seconds . . . . . . . . . . . . . . . . . . . 41
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1012-Foot throttle signal out of range, throttle below 5% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . 44
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1013-Foot throttle signal out of range, signal unusable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1014-Battery charge voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

1015-Battery charge voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1018-Boost air temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1019-Engine coolant temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1020-Transmission oil temperature above normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1021-Fuel temperature above normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1022-Water in fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1023-Foot throttle supply voltage too high, over 5.2 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1024-Foot throttle supply voltage too low, under 4.8 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . 62
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1025-Foot throttle sensor voltage over 5.3 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

580N T4, 580SN T4, 580SN WT T4, 590SN T4
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1026-Foot throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1032-Hand throttle supply voltage too low, under 4.8 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . 71
580N Power Shuttle, 580N T4, 580SN Power Shuttle, 580SN T4, 580SN WT Power Shuttle, 580SN WT T4, 590SN
Power Shuttle, 590SN T4
1033-Hand throttle sensor voltage over 5.3 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

1034-Hand throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1035-Hand throttle sensor signal above 95% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

1036-Hand throttle sensor signal below 5% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

1037-Hand throttle sensor out of range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

1039-Hand throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

1040-Engine RPM over 2750 for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1041-Engine RPM over 3000 for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1045-Fuel level sensor open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1047-Transmission temperature sensor below 3.0 ohms for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . 112

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1050-Alternator L+ terminal under 1.5 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1051-1059- Timeout of CAN message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3006-Coolant Temperature Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3007-Coolant Temperature Signal - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3008-Coolant Temperature Signal - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3010-Air intake temperature sensor signal above maximum range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3011-Air intake temperature sensor signal below minimum range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3015-Fuel Temperature Sensor - Signal Above Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3016-Fuel Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3019-Boost Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3022-Boost Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3023-Atmospheric pressure sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

580N T4, 580SN T4, 580SN WT T4, 590SN T4
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3024-Atmospheric Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3025-Atmospheric pressure sensor - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3028-Oil Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3029-Oil Pressure Sensor - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3030-Oil Pressure Sensor - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3031-Oil Pressure Sensor - Hardware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3032-Oil Pressure Sensor - Value Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3033-Oil Temperature Sensor - Signal Not Plausible (Compared With Coolant Temperature) . . . . . . . 157
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3034-Oil Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3035-Oil Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3037-Boost Pressure Sensor - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3051-Battery Voltage To Engine Controller - Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3052-Battery Voltage To Engine Controller - Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3059-ECM afterrun was interrupted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3060-Cylinder 1 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

3061-Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

3062-Cylinder 1 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175



3070-Cylinder 3 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180




3078-Cylinder 2 - Electronic injector, Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188



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55.DTC / 4
3082-Cylinder 4 - Electronic injector, Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196


3088-Crankshaft sensor lost synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3089-Crankshaft Sensor - Invalid Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3090-Phase defect of camshaft speed sensor signal detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3091-Camshaft sensor phase synchronization failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3093-Offset Between Camshaft And Crankshaft - Outside Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . 212

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3095-Operating With Camshaft Sensor Only - Backup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3096-CAN Bus: Bus Off error CAN A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3104-Rail Pressure Relief Valve - Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3105-Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3106-Rail Pressure Relief Valve - Did Not Open After Pressure Shock . . . . . . . . . . . . . . . . . . . . . . . . . . 228
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3107-Metering unit output short circuit to battery on low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3110-Rail Pressure Sensor Monitoring - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . 230

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3111-Rail Pressure Sensor Monitoring - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . 231

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3118-ECM 12V sensor supply voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3119-ECM 12V sensor supply voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3137-Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3139-Metering Unit Signal Range Check - Signal Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3140-Metering Unit Signal Range Check - Signal Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3141-Set point of fuel volume flow through metering unit is lower than calculated limit . . . . . . . . . . . . . 240
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3146-Water detected in fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3147-Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3171-Fuel rail system pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 5
3172-Fuel rail system pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3173-Rail Pressure Governor Deviation Below Min. Limit for Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3174-Rail Pressure Governor Deviation Exceeded Max. Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3175-Fuel system leak detected - large leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3176-Fuel delivery exceeded threshold for pressure in overrun mode . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3188-Cylinder 1 Warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

3192-Cylinder 2 - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254



3210-Bank 1 - General Short Circuit To Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

3211-Bank 1 - Injector cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

3213-Bank 1 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265

3218-Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

3219-Bank 2 - Injector Cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

3221-Bank 2 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

3227-Injection Processor Error - Internal Reset/Clock Loss/Voltage Too Low . . . . . . . . . . . . . . . . . . . . . 272

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3228-Injection Processor Error - Unlocked/Initialization Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3229-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3235-Number of Injections Limited - by Charge Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3236-Number of Injections Limited - by Quantity Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3237-Number of Injections Limited - by Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3238-Communication error of CJ940 processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 6
3242-Engine Controller (Locked) Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3243-Engine Controller Recovery (Suppressed) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3244-Soft Controller Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3245-Engine Controller - Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3246-Shutoff Paths During Initialization - Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3247-Shutoff Paths Failed During Initialization - Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . 289
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3248-Shutoff Paths During Initialization - Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3252-Controller Watchdog - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3253-ADC Monitoring - Reference Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3254-ADC Monitoring - Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3255-ADC Monitoring Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3256-ADC Monitoring Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3258-HS power stage hardware reports 'short circuit to battery' longer than 500 ms. . . . . . . . . . . . . . . 296
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3259-HS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . 298
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3260-LS power stage hardware reports 'open load' longer than 100 ms . . . . . . . . . . . . . . . . . . . . . . . . . 300
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3261-LS power stage hardware reports 'short circuit to battery' or 'excess temperature' longer than 100
ms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3262-LS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . 303
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3263-Busoff in CAN C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3265-Energizing time exceeds limit of over run monitoring, injection time too long . . . . . . . . . . . . . . . . 306
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3266-Error in engine speed check, speed signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3278-Engine Controller Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3279-Engine Controller Internal Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3280-Sensor Supply Voltage 1 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3281-Sensor Supply Voltage 1 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 7
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3293-Fuel Metering Unit: maximum positive deviation of rail pressure exceeded . . . . . . . . . . . . . . . . . . 324
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3301-Fuel high pressure pump is at minimum delivery and the Rail pressure is not reducing . . . . . . . 325
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3305-Cannot maintain rail pressure above the minimum pressure of 200 Bar . . . . . . . . . . . . . . . . . . . . . 326
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3309-Maximum Fuel rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3334-Timeout of CAN Message TSC1 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3339-Timeout of CAN Message TSC1 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3361-ECM EEPROM - General Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3362-Torque to Quantity Map - Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3363-Atmospheric Pressure Sensor - Processed via ADC, not plausible . . . . . . . . . . . . . . . . . . . . . . . . . 336

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3368-Torque limitation due to performance limiter, may be triggered by inducament . . . . . . . . . . . . . . . 337

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3369-Torque limitation due to smoke limitation has been active for 120 seconds . . . . . . . . . . . . . . . . . . 338
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3370-Torque limitation due to engine protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3371-Torque limitation due to Fuel quantity Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3374-Unit injector NEMA codes are invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3402-Rail pressure sensor: maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3405-ECU Power stages: Open load temperature error on the Turbocharger PWM output power stage
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3406-ECU Power stages: Over temperature error on the Turbocharger PWM output power stage . . . 346
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3408-Lambda sensor: Oxygen concentration implausibly high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3409-Oil pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3410-Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3414-3417-Short circuit in glow plug wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3420-CAN Bus Received frames: DFC of Auxiliary Engine Shutdown Switch Message . . . . . . . . . . . . 361
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3425-Turbocharger: Over boost deviation at P2 too high in pressure charger regulator . . . . . . . . . . . . 362
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3426-Low efficiency in DPF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3517-Atmospheric Temperature Sensor signal range check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364

580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 8
3518-Atmospheric Temperature Sensor signal range check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3616-Torque limitation due to turbo charger protection high altitude operation related . . . . . . . . . . . . . 366
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3648-EVGT Boost pressure monitoring for over boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3650-Battery voltage: SRC high for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3651-Battery voltage: SRC low for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3652-CAN Bus: Bus off of CAN node A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3655-Torque limitation, Engine protection: General report of the event of torque limitations . . . . . . . . 375
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3656-Torque limitation, Engine protection: Torque limitation caused by particulate filter . . . . . . . . . . . . 376
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3663-EGR command saturation over higher threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3664-EGR command saturation over lower threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3667-Open load error for power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3668-Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3669-Short circuit to battery on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3671-Short circuit to ground on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3673-Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3674-Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3675 -DFC for long time valve drift at closed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3676-DFC for valve position sensor voltage SRC high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3677-DFC for valve position sensor voltage SRC low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3680-Injection cut off: Injection cut off demand (ICO) for shut off coordinator . . . . . . . . . . . . . . . . . . . . . 416
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3688-Water sensor in the fuel filter: WIF sensor check is failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3689-Faulty diagnostic data transmission or protocol error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3690-DFC for glow module error in GCU-T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422

580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 9
3691-No load error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3692-Over temperature error on ECU power stage for glow plug low voltage system . . . . . . . . . . . . . . 427
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3693-Short circuit to battery error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3694-Short circuit to ground error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3699-EEPROM: Error in EEPROM block EEPData1, SD correction can not be calculated . . . . . . . . . 435
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3702-Injection control: Detection of failed engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3703-Injection control: check of minimum rail pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3704-3706- Injector adjustment programming: check of missing injector adjustment value programming
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3707-Lambda sensor: Open circuit at the lambda sensor Nernst cell pin . . . . . . . . . . . . . . . . . . . . . . . . . 439
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3708-Lambda sensor: Open circuit at the lambda sensor pump current pin . . . . . . . . . . . . . . . . . . . . . . 441
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3709-Lambda sensor: Open circuit at the lambda sensor virtual ground pin . . . . . . . . . . . . . . . . . . . . . . 443
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3710-Lambda sensor: Fault to indicate dynamics of the sensor signal too small . . . . . . . . . . . . . . . . . . 445
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3711-SCB error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3712-Lambda sensor: SCG error of the LSU heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3713-Lambda sensor: Open Load error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . . . . . . . 451
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3714-Lambda sensor: Fault code to indicate SRC High error for O2 calibration . . . . . . . . . . . . . . . . . . . 453
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3715-Lambda sensor: SRC Low error for O2 calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3720-Lambda sensor: Low battery voltage at the SPI chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3721-Lambda sensor: Fault check to indicate SPI chip error of lambda sensor . . . . . . . . . . . . . . . . . . . 458
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3722-Lambda sensor: LSU sensor temperature Ri exceeds the maximum limit . . . . . . . . . . . . . . . . . . . 459
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3723-Lambda sensor: LSU sensor temperature Ri is below the minimum limit . . . . . . . . . . . . . . . . . . . . 460
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3724-Lambda sensor: Short to battery at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3725-Lambda sensor: Short to ground at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3727-Low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3728-Too low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3735-Fuel Metering Unit: over temperature of device driver of metering unit . . . . . . . . . . . . . . . . . . . . . . 465
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3736-O2 concentration is outside the predefined window during Heater coupling detection . . . . . . . . . 468
580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 10
3738-ECU Internal: Diagnostic fault check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3739-Power stages, Injector: Loss of synchronization sending bytes to the MM from CPU . . . . . . . . . 470
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3740-Power stages, Injector: DFC to set a torque limitation once an error is detected before MoCSOP's
error reaction is set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3741-Power stages, Injector: Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3743-Power stages, Injector : Diagnostic fault check to report the error in under voltage monitoring . 473
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3773-EVGT Turbocharger Control Underboost Pressure failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3786-Diesel particulate filter signal range check is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3787-Diesel particulate filter (DPF) : Signal range check flow resistance of the particulate filter - very high
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3789-Regeneration duration exceeds maximum allowed duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3790-Diesel particulate filter: Signal range check flow resistance of the particulate filter - max . . . . . . 478
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3794-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3796-Diesel particulate filter pressure sensor hose line error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3797-Diesel particulate filter pressure sensor: SRC high for differential pressure sensor . . . . . . . . . . . 484
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3798-Diesel particulate filter pressure sensor: SRC low for differential pressure sensor . . . . . . . . . . . . 487
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3799-Rail system: Rail pressure reduction by blank shots during after run (BSA) aborted during post drive
of ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3800-Pressure relief valve: Quantity balance check if a successful PRV opening is ensured . . . . . . . 491
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3801-Turbine upstream pressure sensor: SRC high for turbine upstream pressure sensor . . . . . . . . . 492
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3802-Turbine upstream pressure sensor: SRC low for turbine upstream pressure sensor . . . . . . . . . . 495
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3803-ECU internal: Internal communication signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3808-Fuel Metering Unit: set point of metering unit in idle mode not plausible . . . . . . . . . . . . . . . . . . . . 499
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3810-Rail pressure raw value is intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3811-ECU sensor supply monitor : ECU internal: Error sensor supplies 1 . . . . . . . . . . . . . . . . . . . . . . . . 501
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3812-Physical range check high for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3813-Physical range check low for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3814-ECU temperature sensor: SPI error ECU temperature sensor (LM71) . . . . . . . . . . . . . . . . . . . . . . 507
580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 11
3815-Low efficiency in DPF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3818-Open load error for power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3820-Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3825-Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3826-Temperature dependent over current error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3827-Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3838-Oxidation catalyst upstream temperature shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . 535

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3839-Oxidation catalyst upstream temperature shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . 538

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3840-Diesel particulate filter upstream temperature sensor shorted to high source . . . . . . . . . . . . . . . . 541
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3841-Diesel particulate filter upstream temperature sensor shorted to low source . . . . . . . . . . . . . . . . . 544
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3844-3847-Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing
time to Max value injector 1, 2, 3 or 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
3848-3851-Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing
time to Min value injector 1, 2 3 or 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
3852-Lambda sensor: The maximum allowed time for blow out is exceeded . . . . . . . . . . . . . . . . . . . . . 549
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3856-Coolant temperature signal test failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3899-Info: Engine temperature exceeded pre-warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3900-Info: Engine temperature exceeded warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3906-Injector: Number of injections is limited by quantity balance of high pressure pump . . . . . . . . . . 554
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3910-Fuel metering unit: Error check for loose contact between metering unit (MeUn) and ECU . . . . 555
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3915-Pressure Relief Valve: Averaged rail pressure is outside the expected range with open PRV . . 556
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3916-Pressure Relief Valve: Open time of PRV for wear out monitoring had exceeded maximum value
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3998-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558

580N T4, 580SN T4, 580SN WT T4, 590SN T4
3999-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560

580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 12
4000-Power supply (pin 2), forward FWD drive (pin 3), or RVS drive (pin 4) drive shorted to ground H-type
and S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
580N Powershift, 580N T4, 580SN Powershift, 580SN T4, 580SN WT Powershift, 580SN WT T4, 590SN Powershift,
590SN T4
4001-Power supply (pin 5), PWM 1 drive (pin 6), or PWM 2 drive (pin 7) drive shorted to ground H-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
590SN T4
4002-Power supply for digital outputs (pin 8) does not have power H-type and S-type transmission . 573
590SN T4
4004-Battery voltage (Pin 34) voltage below 10 volts for 2.5 seconds with engine speed above 900 rpm
H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577
590SN T4
4005-Downshift delayed due to possible engine overspeed condition H-type and S-Type transmission 581
590SN T4
4006-FWD input (Pin 12) feedback circuit is reading current with command H-type and S-type transmission
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582
590SN T4
4007-FWD input (Pin 12) current is too low with command present H-type and S-type transmission . 585
590SN T4
4008-FWD solenoid is drawing more current than commanded H-type and S-type transmission . . . . 588
590SN T4
4009-FWD solenoid is drawing less current than commanded H-type and S-type transmission . . . . . 591
590SN T4
4011-RVS input (pin 40) feedback circuit is reading current with command H-type and S-type transmission
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
590SN T4
4012-RVS input (pin 40) current is too low with command present H-type and S-type transmission . . 597
590SN T4
4013-RVS solenoid is drawing more current than commanded H-type and S-type transmission . . . . . 600
590SN T4
4014-RVS solenoid is drawing less current than commanded H-type and S-type transmission . . . . . . 603
590SN T4
4016-First and third shift modulation solenoid input (pin 13) feedback circuit is reading current without
command H-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
590SN T4
4017-First and third shift modulation solenoid input (pin 13) current is too low with command present H-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
590SN T4
4018-First and third shift modulation solenoid is drawing more current than commanded H-type transmis-
sion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
590SN T4
4019-First and third shift modulation solenoid is drawing less current than commanded H-type transmis-
sion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
590SN T4
47365539 08/07/2012
55.DTC / 13
4021-Second and fourth shift modulation solenoid input (pin 41) feedback circuit is reading current with
command H-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
590SN T4
4022-Second and fourth shift modulation solenoid input (pin 41) current is too low with command present
H-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
590SN T4
4023-Second and fourth shift modulation solenoid is drawing more current than commanded H-type trans-
mission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
590SN T4
4024-Second and fourth shift modulation solenoid is drawing less current than commanded H-type trans-
mission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
590SN T4
4026-First / Third shift solenoid shorted to ground H-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 630

590SN T4
4027-Second / Fourth shift solenoid shorted to ground H-type transmission . . . . . . . . . . . . . . . . . . . . . . 633

590SN T4
4028-Differential lock or 4 wheel drive solenoid shorted to ground H-type and S-type transmission . . 636
590SN T4
4029-Shifter Lever improperly connected, no power to pin 16, pin 18, or pin 46 for more than 3 seconds
H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 639
590SN T4
4030-Shifter Lever malfunction: transmission in neutral receives forward and neutral together H-type and
S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
590SN T4
4031-Shifter Lever malfunction: transmission in neutral receives reverse and neutral together H-type and
590SN T4
4032-Shifter Lever malfunction: transmission in forward receives forward and reverse together H-type and
590SN T4
4033-Shifter Lever malfunction: transmission in reverse receives forward and reverse together H-type and
590SN T4
4034-Shifter Lever malfunction: transmission in forward receives neutral and forward together H-type and
590SN T4
4035-Shifter Lever malfunction: transmission in reverse receives neutral and reverse together H-type and
590SN T4
4036-During transition from second to third gear, and Gear CMD_01 signal erratic or incorrect H-type and
590SN T4
4037-During transition from first to second gear, and Gear CMD_02 signal erratic or incorrect H-type and
590SN T4
47365539 08/07/2012
55.DTC / 14
4038-During transition from third to fourth gear, and Gear CMD_02 signal erratic or incorrect H-type and
590SN T4
4040-Transmission Controller Driveline Configuration H-type and S-type transmission . . . . . . . . . . . . . 688

590SN T4
4041-Transmission output shaft frequency above 3000 Hz detected H-type and S-type transmission 689
590SN T4
4042-Temperature signal erratic or incorrect H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . 692

590SN T4
4043-Temperature sensor input (Pin 43) is shorted to a ground H-type and S-type transmission . . . . 695
590SN T4
4044-Temperature sensor input (Pin 43) is open circuit or shorted to a voltage above 5 volts H-type and
590SN T4
4045-Charge pressure is not detected when engine speed is above 700 rpm for 10 seconds H-type and
590SN T4
4046-Charge pressure is not detected and vehicle speed is over 10 kph (6 mph) H-ype and S-type trans-
mission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
590SN T4
4047-Charge pressure switch is closed with no frequency input to the TRAX controller H-type and S-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
590SN T4
4054-Unknown vehicle model value from VCM S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710

590SN T4
4100-Missing EEC 1 message on CAN H-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711

590SN T4
4101-Internal TRAX failure, hardware measurement H-type and S-type transmission . . . . . . . . . . . . . . 715
590SN T4
4102-Internal TRAX failure, software timing H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . 716
590SN T4
4103-Internal TRAX failure, software not running H-type and S-type transmission . . . . . . . . . . . . . . . . . 717
590SN T4
4105-Internal TRAX failure, redundant flash memory H-type and S-type transmission . . . . . . . . . . . . . 718
590SN T4
4106-Internal TRAX failure, sensor supply high H-type and S-type transmission . . . . . . . . . . . . . . . . . . 719
590SN T4
4107-Internal TRAX failure, sensor supply low H-type and S-type transmission . . . . . . . . . . . . . . . . . . . 723
590SN T4
4200-First shift solenoid shorted to ground S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727

590SN T4
47365539 08/07/2012
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4203-Fourth shift solenoid shorted to ground S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730
590SN T4
4204-System detects different gear than commanded S-type transmission . . . . . . . . . . . . . . . . . . . . . . . 733

590SN T4
4205-System can not engage required gear. (Engaged gear is different than requested gear) S-type trans-
mission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740
590SN T4
4206-Gear engagement failed S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 742

590SN T4
4207-1ST/2ND gear shift rail position reporting first gear at startup S-type transmission . . . . . . . . . . . 744
590SN T4
4208-1ST/2ND gear shift rail position reporting second gear at startup S-type transmission . . . . . . . . 746
590SN T4
4209-3RD/4TH gear shift rail position reporting third gear at startup S-type transmission . . . . . . . . . . . 748
590SN T4
4210-3RD/4TH gear shift rail position reporting forth gear at startup S-type transmission . . . . . . . . . . 750
590SN T4
4211-First and second gear sensor input shorted to ground S-type transmission . . . . . . . . . . . . . . . . . . 752
590SN T4
4212-First and second gear sensor input voltage too high S-type transmission . . . . . . . . . . . . . . . . . . . 755
590SN T4
4213-Third and forth gear sensor input shorted to ground S-type transmission . . . . . . . . . . . . . . . . . . . 758
590SN T4
4214-Third and forth gear sensor input voltage too high S-type transmission . . . . . . . . . . . . . . . . . . . . . 761
590SN T4
4825-Loss of TC1 message after 15 seconds H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . 764
590SN T4
4850-Possible detection wrong transmission type for installed software H-type and S-type transmission
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 765
590SN T4
4995-Incorrect VCM configuration of transmission type H-type and S-type transmission . . . . . . . . . . . 766
590SN T4
4996-Electronic transmission offline or incorrect VCM configuration of transmission type H-type and S-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 767
590SN T4
4997-Loss of messaging from Trax controller H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . 768
590SN T4
4998-Unknown transmission error code with amber lamp H-type and S-type transmission . . . . . . . . . 773
590SN T4
4999-Unknown transmission error code with red lamp H-type and S-type transmission . . . . . . . . . . . . 774
590SN T4
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9001-Hour meter plausibility, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 775
580N T4, 580SN T4, 580SN WT T4, 590SN T4
9002-Hour meter RAM checksum failure, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776

580N T4, 580SN T4, 580SN WT T4, 590SN T4
9003-J1939 receive buffer overflow, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777

580N T4, 580SN T4, 580SN WT T4, 590SN T4
9004-EEPROM checksum failure, hour meter location 1, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . 778

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4

580N T4, 580SN T4, 580SN WT T4, 590SN T4
9007-Abnormal reset watchdog time-out, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 781

580N T4, 580SN T4, 580SN WT T4, 590SN T4
9008-A/D fault foot throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 782

580N T4, 580SN T4, 580SN WT T4, 590SN T4
9009-A/D fault foot throttle power, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 783

580N T4, 580SN T4, 580SN WT T4, 590SN T4
9010-A/D fault hand throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784

580N T4, 580SN T4, 580SN WT T4, 590SN T4
9011-A/D fault foot throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785

580N T4, 580SN T4, 580SN WT T4, 590SN T4
9012-A/D fault, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 786

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3047-Main Relay Failure - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 787

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3048-Main Relay Failure - Short Circuit to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 789

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3108-Fuel Metering Unit - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3138-Metering Unit - Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3142-High Pressure Test - Test Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 793

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3145-Terminal 15 - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 794

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3177-Engine Overspeed Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 796

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3239-Engine Controller EEPROM - Read Operation Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 797

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3240-Engine Controller EEPROM - Write Operation Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 798

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3241-Engine Controller EEPROM - Default Value Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 799

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3249-TPU Monitoring - Time Deviation Between TPU And System Not Plausible . . . . . . . . . . 800
580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3250-Dataset - Variant Defect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3251-Dataset - Requested Variant Could Not Be Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3316-Minimum Number Of Injections Not Reached - Stop Engine . . . . . . . . . . . . . . . . . . . . . . . 803

580N T4, 580SN T4, 580SN WT T4, 590SN T4
[EDC] - 3358-CAN transmit timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804

580N T4, 580SN T4, 580SN WT T4, 590SN T4
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Electrical systems - FAULT CODES
0000-Retrieving fault codes, Backhoes

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTE: The Electronic Service Tool must be used to remove faults from memory.
Context:
General fault code identification and response.
Cause:
General fault code description.
Possible failure modes:
1. List of possible failure modes.
Solution:
1. Press the enter key once.
BD08E038-01 1
(A) Escape key (C) Up key

(B) Enter key (D) Down key
2. Press the down arrow until a warning icon is displayed.
BD08E036-01 2
47365539 08/07/2012
55.DTC / 18
3. Press ENTER to view faults.
BD08E037-01 3
(A) Fault Number (D) Number of occurrences of this fault

(B) Number of faults (E) The hour reading on the machine of the last
occurrence
(C) Fault code
4. The screen will automatically scroll to the next fault.

5. Press the ESCAPE key to return.
6. Fault Code Grouping
(1) 1000 to 1999 vehicle errors.

(2) 2000 to 2999 not used.
(3) 3000 to 3999 engine errors.
(4) 4000 to 4999 transmission errors.
(5) 5000 to 5999 not used.
(6) 6000 to 6999 not used.
(7) 7000 to 7999 not used.
(8) 8000 to 8999 not used.
(9) 9000 to 9999 internal AIC errors.
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1001-Engine Air Filter Blocked

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster detects a signal to ground on pin 16 indicating that the Air Filter Restriction Switch has been
tripped. The Instrument Cluster will illuminate the Air Filter Restriction Lamp while this fault is active.
Cause:
The Instrument Cluster detects a signal to ground indicating that the Air Filter Restriction Switch has been tripped.
1. Clogged air filter.

2. Signal wire short circuit to minus battery or chassis ground.
3. Faulty air filter restriction switch.
4. Faulty Instrument Cluster.
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
Prior to clearing fault codes write down all fault codes, number of occurrences, and engine hours at last occur-
rence.
RCPH11TLB015FAL 1
(1) Use the Electronic Service Tool to clear all fault codes.
(2) To check for Active fault codes: Start and operate machine.
A. OK – Fault is not recorded again. OK to return the machine to service.
B. NOT OK – Fault code 1001 is recorded again. Go to Step 2.

2. Inspect the engine air filter.
(1) Inspect the engine air filter. Replace the filter if needed.
47365539 08/07/2012
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RCPH11TLB004BAD 2
A. OK – The filter is OK and does not need to be replaced. Go to 3.
B. NOT OK – The filter is in poor condition or is clogged. Replace the filter. Go to Step 1 to confirm elimination
of the fault.
3. Verify that the wiring and connectors are free of damage.
RCPH10TLB054FAM 3
Schematic legend
(1) Air Filter Restriction Switch (3) GND005 Chassis Ground On Upright
(2) Instrument Cluster
(1) Inspect the Instrument Cluster and the Air Filter Restriction Switch connections. All connections should be
secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster and the Air Filter Restriction Switch. Verify that the harness
is free of damage, corrosion, abrasion and incorrect attachment.
A. OK – The connectors are secure and the harness is free of damage. Go to Step 3.
B. NOT OK – The connectors or the harness has damage. Repair or replace the harness or connectors as
required. Return to Step 1 to confirm elimination of fault.
4. Check Air Filter Restriction Circuit
47365539 08/07/2012
55.DTC / 21
BD08D002-01 4
(1) Air filter restriction switch

(2) Connector air filter restriction switch
(1) Disconnect 3801-BL from air filter restriction switch.
(2) Turn the key switch on. Engine off. The Air Filter Restriction fault code should no longer be Active.
A. OK – The fault code is no longer active. Go to Step 4.
B. NOT OK – Fault code 1001 is still active. Go to step 5.

5. Check air filter restriction switch
(1) Remove the air filter restriction switch from the air filter housing.
(2) Measure the resistance across the switch. The resistance should be greater than 20,000 ohms.
A. OK – The resistance is greater than 20,000 ohms. Inspect the wiring around the sensor. Go to Step 5.
B. NOT OK – The resistance is less than 20,000 ohms. Replace the air filter restriction switch. Return to
Step 1 to confirm elimination of fault.
6. Measure the resistance of the signal wire.
BD08E042-01 5
(1) Instrument cluster connector 1

(1) Measure the resistance from X-28 pin 16 to chassis ground. The resistance should be greater than 20,000
ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The resistance is greater than 20,000 ohms. Temporarily replace the Trax Control and retest. Go to
Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short to chassis ground in the signal wire.
Repair or replace the wire as required. Return to Step 1 to confirm elimination of fault.
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Wire harnesses - Electrical schematic frame 12 (55.100.DP-C.20.E.12)
47365539 08/07/2012
55.DTC / 23
1002-Engine coolant temperature too high, critical

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTICE: Check coolant level before proceeding.
Context:
The Instrument Cluster has detected a coolant temperature above 111 °C (232 °F) for a period greater than 5 seconds.
The Instrument Cluster will illuminate the Coolant Temperature Icon and the Danger Icon . The audible alarm
will sound continuously while this fault is active.
Cause:
The coolant temperature signal is above normal. The Instrument Cluster has detected a coolant temperature above
111 °C (232 °F) for a period greater than 5 seconds.
1. Low coolant level.

2. Wiring or circuits shorted to ground.
3. Faulty reading from component.
Solution:
rence.
RCPH11TLB015FAL 1
(2) To check for fault code: Start and operate machine.
A. OK – Fault code is not recorded again. OK to return the machine to service.
47365539 08/07/2012
55.DTC / 24
2. Visually inspect cooling system.
(1) Run engine at 1500 RPM.
(2) Check fan operation.
(3) Check cooling core for clogs.
A. OK – The fan is operating properly and there are no clogs in the system. Go to Step 3.
B. NOT OK – The fan is not operating properly or the radiator is clogged. Repair as required. Return to Step
1 to confirm elimination of fault.
3. Check engine coolant temperature sensor.
23119857 2
RCPH10TLB046FAM 3
Schematic legend
(1) Coolant Temperature Sensor (3) Chassis Ground, (sensor is internally
grounded to chassis ground)
(1) Disconnect the terminal from the coolant temperature sender.
(2) Measure the resistance of the temperature sender to chassis ground.
Temperature Open circuit resistance in ohms

110 °C (230.0 °F) 130 Ω
100 °C (212.0 °F) 175 Ω
47365539 08/07/2012
55.DTC / 25

92 °C (197.6 °F) 223 Ω
85 °C (185.0 °F) 280 Ω
78 °C (172.4 °F) 358 Ω
68 °C (154.4 °F) 511 Ω
A. OK – The resistance measurement was within the values stated in the table above. Go to Step 4.
B. NOT OK – Resistance reading is not acceptable. Replace the transmission temperature sender. Return
to Step 1 to confirm elimination of fault.
4. Check wiring to Instrument Cluster
BD08E042-01 4

(1) Disconnect Instrument Cluster connector X 29.
(2) Measure the resistance from Coolant Temperature sender connector pin 1 to chassis ground. The resis-
tance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent
condition.
A. NOT OK – Determine the break between connectors and repair. Return to Step 1 to confirm elimination
of fault.
B. OK – Go to Step 5.
5. Replace the instrument cluster.
(1) Remove and replace the instrument cluster.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again, contact Technical Services Group
for assistance
47365539 08/07/2012
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1003-Air conditioning pressure too high

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster measures 12 volts on connector X-28 pin 10. The Instrument Cluster will illuminate the Air
Conditioning Icon while the fault is active and will sound the alarm for one second on the next system power up
following the event.
Cause:
The Instrument Cluster has detected the air conditioning pressure to be greater than 27.6 bar (400 psi).
1. Air conditioning pressure greater than 27.6 bar (400 psi).

2. Faulty reading from pressure switch.
3. Wiring or circuit shorted to positive battery.
4. Connectors not mated fully, pins not seated properly in connector, bent pin or broken wires at rear of connector.
5. Faulty A/C Relay (K-008).
Solution:
rence.
RCPH11TLB007FAL 1
(2) To check for fault code: Start the engine. Turn the A/C (air conditioner) temperature switch to the cold
position and the blower switch to the high position.
A. OK – Fault 1003 is not recorded again. OK to return the machine to service.
47365539 08/07/2012
55.DTC / 27
2. Verify the harness is not damaged.
(1) Inspect the Instrument Cluster and A/C High Pressure switch and the A/C Relay (K-008) connections. All
connections should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster to the A/C High Pressure switch and the A/C Relay (K-008).
Verify that the harness is free of damage, corrosion, abrasion or incorrect attachment.
RCPH11TLB050FAL 2
(1) Thermostat switch S-019 (5) AC Low Pressure Switch S-026

Switched open in fault condition.
(2) AC Relay, K-008 (6) Blower switch signal from fuse F-023.
(3) AC High Pressure Switch S-027 (7) AC Relay Ground
Switched closed in fault condition.
(4) AC Compressor (8) Fault signal to Instrument Cluster con-
nector X-028 pin 10.
A. OK - The wiring is free of corrosion, damage, abrasion and incorrect attachment. Go to Step 3.
B. NOT OK - The wiring is not free of corrosion, damage, abrasion and incorrect attachment. Repair or
replace the harness as required. Go to Step 1 to confirm elimination of the fault.
3. Check air conditioning system pressure.
(1) Install a gauge capable of measuring a minimum of 27.6 bar (400 psi) on the A/C High Side test port.
(2) Turn the key switch ON. Turn the A/C (air conditioner) temperature switch to the cold position and the blower
switch to the high position.
(3) Measure the pressure at the high side test port. The pressure should be less than 27.6 bar (400 psi).
BD08F240-01 3
47365539 08/07/2012
55.DTC / 28
(1) Connector A/C High Pressure Switch

(Connector is located behind grill on front of machine)
(2) Cooling pack
(3) A/C Highside Test Port
A. OK – The pressure is below 27.6 bar (400 psi) Go to Step .4.
B. NOT OK – The pressure is above 27.6 bar (400 psi). Repair or replace air conditioning system. Return
4. (1) Start the engine. Turn the A/C (air conditioner) temperature switch to the cold position and the blower switch
to the high position.
(2) Disconnect the high pressure switch (S-027). The fault code should no longer be active.
A. OK - The fault code in not active when the pressure switch is disconnected and the fault code is active
when the switch is reconnected. Replace the switch. Go to Step 1 to confirm elimination of the fault.
B. NOT OK - The fault code is active while the switch is disconnected. Go to Step 5.
5. Check Instrument Cluster signal pin.
(1) Disconnect the A/C High Pressure Switch input pin to the Instrument Cluster. Remove pin 10 (60A5 BN A/C
Fault Signal) on connector X-28.
(2) Turn the ignition switch to the ON position, turn the A/C (air conditioner) temperature switch to the cold
position and the blower switch to the high position.
A. OK – The fault code 1003 is not active when the pin is removed and the key switch is ON. Reinstall wire
60A5 BN A/C Fault Signal into instrument cluster connector X-28, pin 10. Go to Step 6.
B. NOT OK – Fault code 1003 is still active. Temporarily replace the instrument cluster and retest. Return to
6. Check the A/C Relay
(1) Turn ignition switch to the OFF position.
(2) Remove the A/C Relay K-008. Inspect the pins and wiring to the relay.
RCPH10TLB302AAF 4
(1) Fuse block

(2) Diagnostic port
(3) Turn the key switch ON. Turn the A/C (air conditioner) temperature switch to the cold position and the blower
switch to the high position. Fault code 1003 should not be active.
A. OK – The fault code is not active when relay K-008 removed. Replace the relay. Go to Step 1 to confirm
elimination of the fault code.
47365539 08/07/2012
55.DTC / 29
B. NOT OK – The fault code 1103 is active with relay K-008 removed. There is a short circuit to positive
battery in the wiring harness. Repair or replace the harness as needed. Go to Step 1 to confirm elimination
of the fault code. .
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55.DTC / 30
1004-Hydraulic filter blocked

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster measures 0 volts on connector X-28 pin 17. The Instrument Cluster will illuminate the Hy-
draulic Filter Restriction Icon while the fault is active and will sound the alarm for one second on the next system
power up following the event.
Cause:
The Instrument Cluster measures 0 volts on connector X-28 pin 17.
1. Clogged hydraulic filter

2. Faulty reading from switch
3. Signal wire short to ground
Solution:
Prior to clearing fault codes, write down all fault codes, number of occurrences and engine hours at last occur-
rence.
RCPH11TLB007FAL 1

2. Inspect Hydraulic Filter.
(1) Inspect the hydraulic filter. Replace the filter if needed.
47365539 08/07/2012
55.DTC / 31
RCPH10TLB045AAF 2
A. OK – The filter is OK and does not need to be replaced. Go to 3.
B. NOT OK – The filter is in poor condition or is clogged. Replace the filter. Go to Step 3 to confirm elimination
of the fault.
3. Verify the harness and connectors are not damaged.
(1) Inspect the Instrument Cluster and Hydraulic Filter Restriction Switch connections. All connections should
be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster to the Hydraulic Filter Restriction Switch. Verify that the
harness is free of damage, corrosion, abrasion or incorrect attachment.
RCPH11TLB051FAL 3
Schematic legend
(1) Instrument Cluster, connector X-028 (4) Fuel Level Sender, B-017
(2) Air Filter Restriction Switch, S-033 (5) Transmission Temperature Sender, B-018
Switched closed in fault condition
(3) Hydraulic Filter Restriction Switch, S-034
Switch closed in fault condition
47365539 08/07/2012
55.DTC / 32
RCPH10TLB016GAM 4
(1) Hydraulic oil filter restriction switch

(2) Filter head
A. OK - The wiring is free of corrosion, damage, abrasion and incorrect attachment. Go to Step 3.
B. Not OK - The wiring is not free of corrosion, damage, abrasion and incorrect attachment. Repair or replace
the harness as required. Go to Step 1 to confirm elimination of the fault.
4. Measure the resistance of the Filter Restriction Switch.
(1) Measure the resistance between the filter bypass switch housing and filter head. The resistance should be
greater than 20,000 ohms.
A. OK – The resistance is greater than 20,000 ohms. Go to Step 5.
B. NOT OK – The resistance is less than 20,000 ohms. Replace hydraulic filter bypass switch and retest.
Return to Step 1 to confirm elimination of fault.
5. Check hydraulic filter bypass switch.
(1) Disconnect connector 223-1 (circuit 36H3) from filter bypass switch.
(2) Measure the resistance from the Filter Bypass Switch terminal 1 to chassis ground. Wiggle the harness
during measurement to reveal an intermittent condition. The resistance should be greater than 20,000 ohms.
B. NOT OK – The resistance is less than 20,000 ohms. Replace hydraulic filter bypass switch and retest.
6. Check circuit 36H for short to chassis ground.
BD08E042-01 5

47365539 08/07/2012
55.DTC / 33
(1) Disconnect Instrument Cluster Connector X 28. Measure the resistance between pin 17 and chassis ground.
The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an
intermittent short condition.
(2) Measure the resistance from 36H3 to ground. The resistance should be greater than 20,000 ohms. Wiggle
the harness during measurement to reveal an intermittent short circuit condition.
A. OK – The resistance is greater than 20,000 ohms. Temporarily replace the Instrument Cluster and retest.
Go to Step 6 to confirm elimination of the fault.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground. Repair or
replace the signal wire as required. Return to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 34
1009-Transmission oil temperature too high

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster monitored a Transmission Oil Temperature greater than 115 °C (239 °F) for a period greater
than 5 seconds.
Cause:
The Transmission Oil Temperature is above 115 °C (239 °F) for a period greater than 5 seconds.
1. Low transmission oil level

2. Faulty fan operation
3. Clogged cooling core
4. Faulty reading from sensor
5. Faulty instrument cluster
Solution:
rence.
RCPH11TLB007FAL 1
A. OK – Fault is not recorded again. OK for return to service.

2. Verify transmission oil level.
(1) Check transmission oil level, add oil as required. Refer to Operator's Manual for more details.
47365539 08/07/2012
55.DTC / 35
A. OK – The oil level is correct and the fault is not recorded again. OK for return to service.
B. NOT OK – The oil level is correct but the fault is recorded again, go to Step 3
3. Stop machine operations.
A. OK – The cooling system is operating properly. Go to Step 4.
B. NOT OK – The cooling system is not operating properly or the cooling core is clogged. Repair fan or clear
clogs from cooling core. Repair as required. Return to Step 1 to confirm elimination of fault.
4. Check temperature sender.
BD00M233-01 2
NOTE: Standard transmission. Top view of transmission looking down through the floor plate.
(1) Shift lever

(2) Transmission temperature sender
BD08E063-01 3
NOTE: Power shift transmission. Bottom view of sensor looking up.
(1) Transmission temperature sender

(2) Trax controller temperature sender
(1) Disconnect terminal connector from the transmission temperature sender.
(2) Measure the resistance from the Transmission Temperature sender ground connection to chassis ground.
The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent
condition.
(3) Measure the resistance across the temperature sender.
47365539 08/07/2012
55.DTC / 36

110 °C (230.0 °F) 130 Ω
100 °C (212.0 °F) 175 Ω
92 °C (197.6 °F) 223 Ω
85 °C (185.0 °F) 280 Ω
78 °C (172.4 °F) 358 Ω
68 °C (154.4 °F) 511 Ω
A. OK – The resistance measurements were within range, go to Step 5.
B. NOT OK – Resistance reading is not acceptable for a room temperature sender. Replace the transmission
temperature sender. Return to Step 1 to confirm elimination of fault.
5. Check wiring to Instrument Cluster
BD08E042-01 4

(1) Disconnect Instrument Cluster connector X 29.
(2) Measure the resistance from Transmission Temperature sender connector (X 29) pin 1 (signal wire) to chas-
sis ground. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to
reveal an intermittent condition.
A. OK – The resistance measurement is greater than 20,000 ohms. Temporarily replace the Instrument Clus-
ter and retest. Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the wire.
Repair or replace the wire as required. Return to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 37
1010-Foot throttle signal out of range, IVS not changing state in

300 ms
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The IVS (idle validation signal) did not change from a high state (+12 volts) to a low state (0 volts) when the throttle
moved off of low idle. The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one
second, on the next system power up following the event.
Cause:
The IVS did not change state in 0.3 sec after the throttle was moved off of low idle.
1. Faulty wiring or connections.

2. Faulty reading from foot throttle sensor.
3. Faulty Instrument Cluster
Solution:
Prior to clearing fault codes, write down all fault codes, the number of occurrences and engine hours of last
occurrence.
(2) To check for fault code: Start the engine and actuate the throttle.
A. OK – Fault is not recorded again. OK for return the machine to service.

2. Measure the voltage at throttle sensor.
BD08E027-01 1
(1) Throttle position sensor connector

(2) Foot throttle assembly
(3) Throttle position sensor
(1) Turn the key switch OFF. Disconnect the foot throttle connector and inspect pins and wiring for damage,
corrosion, abrasion or incorrect attachment.
(2) Turn the ignition switch to the ON position.
(3) Measure the voltage from pin B to pin C. The voltage should be between 4.8 volts and 5.2 volts. Wiggle the
harness during measurement to reveal an intermittent condition.
47365539 08/07/2012
55.DTC / 38
A. OK — The voltage is correct. Go to Step 3.
B. NOT OK — The voltage is greater than 5.2 volts go to procedure 1023-Foot throttle supply voltage
too high, over 5.2 volts for 5 seconds (55.525) OR the voltage is less than 4.8 volts, go to procedure
1024-Foot throttle supply voltage too low, under 4.8 volts for 5 seconds (55.525).
3. Check idle validation circuit
RCPH10TLB018GAM 2
Throttle Signal Legend

(1) Idle Validation Signal (3) Throttle movement in degrees of travel. 0
degrees equals low idle. 20 degrees equals
WOT (Wide Open Throttle).
(2) Throttle Signal Voltage
This step is used to monitor the throttle validation signal. The sensor must be connected and active in order to
continue. The dealer must provide a breakout Tee or connector back probes in order to complete this procedure.
47365539 08/07/2012
55.DTC / 39
RCPH11TLB052FAL 3
Schematic legend
(1) Foot Throttle (3) Dealer supplied breakout T
(1) Turn the key switch ON, engine OFF. Measure the voltage from pin E to pin B. The voltage should be ap-
proximately 12 volts.
(2) Move the throttle approximately 3 degrees. The idle validation signal should change from 12 volts to 0 volts.
A. OK — The signal changed from 12 volts to 0 volts. Go to Step 4.
B. NOT OK — The voltage was not correct or the voltage did not change from 12 volts to 0 volts as the throttle
moved off of low idle. Replace the sensor and retest. Return to step 1 to confirm elimination of fault.
4. Check the wire harness from the sensor to the Instrument Cluster.
(1) Turn the key switch OFF.
(2) Remove the breakout harness and reconnect the sensor to the Instrument Cluster harness.
(3) Remove pin 20 from connector X-28.
(4) Turn the key switch ON, engine OFF.
(5) Measure the voltage from the removed wire, pin 20 to X-29 pin 20 (Ground). Move the throttle approximately
3 degrees. The idle validation signal should change from 12 volts to 0 volts. The signal should stay at 0 volts
as the throttle is moved to WOT (wide open throttle).
A. OK — The voltage changed from 12 volts to 0 volts when the throttle was moved. Temporarily replace the
Instrument Cluster and retest. Go to Step 1 to confirm elimination of the fault.
B. NOT OK — The voltage was not correct or voltage did not change from 12 volts to 0 volts as the throttle
moved off of low idle. There is a problem with the idle validation signal wire from the sensor to the Instru-
ment Cluster. Replace the wire. Return to step 1 to confirm elimination of fault.
47365539 08/07/2012
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1011-Foot throttle signal out of range, throttle above 95% of input

for 5 seconds
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster measured a foot throttle signal greater than 4.75 Volts. The Instrument Cluster will illuminate
the Warning Lamp and will sound the alarm for one second on the next system power up following the event.
Cause:
The Instrument Cluster monitored a throttle signal greater than 4.75 volts (95%) for a period greater than 5 seconds.

Solution:
occurrence.
(2) To check for fault code: Start and operate machine. Wiggle the harness to reveal an intermittent condition.

2. Check voltage at throttle sensor.
BD08E027-01 1

(1) Turn the key switch OFF. Disconnect the foot throttle connector and inspect pins.
47365539 08/07/2012
55.DTC / 41
3. Check the throttle signal from the sensor.
RCPH10TLB017GAM 2

(1) Idle Validation Signal
(3) Throttle movement in degrees of travel. 0 degrees equals low idle. 20 de-
grees equals WOT (Wide Open Throttle).
47365539 08/07/2012
55.DTC / 42
RCPH11TLB052FAL 3
Schematic legend
(1) Foot Throttle (3) Breakout Tee
(1) Connect the break out Tee and measure the voltage from pin A to pin B (or slide Back Probes into pin A and
B).
(3) Measure the voltage from pin A to pin B. Move the throttle from low idle to WOT (wide open throttle). The
voltage should change from approximately 0.55 volts at low idle to 4.2 volts at WOT.
A. OK — The voltage measurement is correct. Go to Step 4.
B. NOT OK — The voltage did not change from 0.55 volts to 4.2 volts as the throttle moved from low idle to
WOT or the voltage was greater than 4.75 volts at WOT. Replace the sensor. Return to step 1 to confirm
elimination of fault.
4. Measure the throttle signal from the sensor to the Instrument Cluster.
(4) Turn the key switch ON, engine OFF. Measure the voltage from removed wire, pin 16 to X-29 pin 20 (Ground).
Move the throttle from low idle to WOT (wide open throttle). The voltage should change from approximately 0.55
volts at low idle to 4.2 volts at WOT.
A. OK — The voltage changed from approximately 0.5 volts to 4.2 volts. Temporarily replace the Instrument
Cluster and retest. Go to Step 1 to confirm elimination of the fault.
WOT or the voltage was greater than 4.75 volts at WOT. There is a problem in the throttle signal wire from
the sensor to the Instrument Cluster. Replace the wire. Return to step 1 to confirm elimination of fault.
47365539 08/07/2012
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1012-Foot throttle signal out of range, throttle below 5% of input

for 5 seconds
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster measures a foot throttle signal less than 0.5 Volts. The Instrument Cluster will illuminate the
Warning Lamp and will sound the alarm for one second on the next system power up following the event.
Cause:
The Instrument Cluster monitored a throttle signal less than 0.5 volts (5%) for a period greater than 5 seconds.
1. Faulty wiring or connections shorted to ground.

Solution:
occurrence.

BD08E027-01 1

47365539 08/07/2012
55.DTC / 44
RCPH10TLB017GAM 2

47365539 08/07/2012
55.DTC / 45
RCPH11TLB052FAL 3
Schematic legend
B).
WOT or the voltage was less than 0.5 volts at low idle. Replace the sensor and retest. Return to step 1 to
confirm elimination of fault.
WOT or the voltage was less than 0.5 volts at low idle. There is a problem in the throttle signal wire from
the sensor to the Instrument Cluster. Repair or replace the wire as required. Return to step 1 to confirm
47365539 08/07/2012
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1013-Foot throttle signal out of range, signal unusable

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster measures a foot throttle signal that is unstable. The Instrument Cluster will illuminate the
Warning Lamp and will sound the alarm for one second on the next system power up following the event.
Cause:
The Instrument Cluster monitors a fluctuation in the throttle signal that is not possible.

Solution:
occurrence.

BD08E027-01 1

47365539 08/07/2012
55.DTC / 47
3. Measure the throttle signal from the sensor.
RCPH10TLB017GAM 2
Idle Validation, Throttle Signal Legend

47365539 08/07/2012
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RCPH11TLB052FAL 3
Schematic legend
(1) Connect the breakout Tee and measure the voltage from pin A to pin B (or slide Back Probes into pin A and
B).
voltage should change from approximately 0.55 volts at low idle to 4.2 volts at WOT. Wiggle the sensor harness
to reveal an intermittent condition.
WOT or there were voltage fluctuations or spikes as the throttle was moved. Replace the sensor. Return
to step 1 to confirm elimination of fault.
A. OK — The throttle signal voltage changed from 0.55 volts to 4.2 volts. Temporarily replace the Instrument
WOT or there were voltage fluctuations or spikes as the throttle was moved. There is a problem in the
throttle signal wire from the sensor to the Instrument Cluster. Replace the wire. Return to step 1 to confirm
47365539 08/07/2012
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1014-Battery charge voltage too high

Context:
The Instrument Cluster measured an alternator voltage greater than 16 V for a period greater than 5 s. The Instrument
Cluster will illuminate the battery warning symbol indicating that it has detected a problem in the battery charging
system.
Cause:
The alternator output is greater than 16 V.
1. Faulty alternator, alternator output greater than 16 V.

Solution:
rence.
RCPH11TLB007FAL 1
(2) To check for Active fault code: Start and operate machine.

2. Measure the alternator output.
(1) Start the engine. Set engine speed to low idle and measure the voltage at the Alternator. The voltage should
be approximately 14.5 V.
A. OK – The voltage is approximately 14.5 V. Go to Step 3.
47365539 08/07/2012
55.DTC / 50
B. NOT OK – The voltage is greater than 16 V. Replace the alternator. Go to test Step 1 to confirm elimination
of fault.
3. Measure the voltage at instrument cluster.
RCPH11TLB056FAL 2
Schematic Legend
YE
(1) Disconnect the Instrument Cluster Connector 2 (X 29). Inspect pins, wiring and connectors for damage,
abrasion, corrosion or incorrect attachment. Measure the voltage on pin X-29 pin 24 to X-29 pin 26. The voltage
should be approximately 14.5 V. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage is approximately 14.5 V. Temporarily replace the Instrument Cluster and retest. Go to
Step 1 to confirm elimination of the fault code.
B. NOT OK – The voltage is greater than 16 V. Replace the alternator. Return to Step 1 to confirm elimination
of fault.
47365539 08/07/2012
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1015-Battery charge voltage too low

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTICE:
Context:
The Instrument Cluster measured an alternator voltage less than 11 V for a period greater than 5 s. The Instrument
Cluster will illuminate the battery warning symbol indicating that it has detected a problem in the battery charging
system.
Cause:
The alternator output is less than 11 V.
1. Instrument Cluster signal wire shorted to chassis ground.

2. Faulty alternator, alternator output less than 11 V.
Solution:
rence.
RCPH11TLB007FAL 1

2. Measure the alternator output.
47365539 08/07/2012
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(1) Start the engine. Set engine speed to low idle and measure the voltage at the Alternator. The voltage should
be approximately 14.5 V.
A. OK – The voltage is approximately 14.5 V. Go to Step 3.
B. NOT OK – The voltage is less than 11 V. Replace the alternator.1 to confirm elimination of fault.
RCPH11TLB056FAL 2
Schematic Legend
YE
(1) Disconnect the Instrument Cluster Connector 2 (X 29). Inspect pins, wiring and connectors for damage,
abrasion, corrosion or incorrect attachment. Measure the voltage on X-29 pin 24 to X-29 pin 26. The voltage
should be approximately 14.5 V. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage measurement is correct. Temporarily replace the Instrument Cluster and retest. Go to
Step 1 to confirm elimination of the fault code.
B. NOT OK – The voltage is less than 11 V. Replace the alternator and retest. Return to Step 1 to confirm
47365539 08/07/2012
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1018-Boost air temperature too high

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
The engine inlet air temperature is greater than 95 °C (203 °F) for a period greater than 5 seconds. The Instrument
Cluster will illuminate the amber warning light while the fault is active.
Solution:
1. Fault Code 1018 is a CAN Data Link message from the ECU to the Instrument Cluster. This fault code is dis-
played on the Instrument Cluster to warn the operator of a high boost temperature warning. Refer to the engine
troubleshooting guide for more information.
RCPH11TLB007FAL 1
47365539 08/07/2012
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1019-Engine coolant temperature too high

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
The coolant temperature is greater than 107 °C (224 °F) for a period greater than 5 seconds. The Instrument Cluster
will illuminate the amber warning light while the fault is active.
Solution:
1. This is an information fault code only. The fault code is logged and indicates that the coolant temperature is
approaching the fault code trigger point.
2. Verify proper coolant level.
played on the Instrument Cluster to warn the operator of a high coolant temperature warning. Refer to the engine
RCPH11TLB007FAL 1
47365539 08/07/2012
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1020-Transmission oil temperature above normal

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
The transmission oil temperature is greater than 105 °C (221 °F) for a period greater than 5 seconds. The Instrument
Cluster will illuminate the amber warning light while the fault is active.
Solution:
1. This is an information fault code only. The fault code is logged and indicates that the transmission oil temperature
is approaching the fault code trigger point.
2. Verify proper transmission oil level.
played on the Instrument Cluster to warn the operator of a high transmission oil temperature warning. Refer to
the engine troubleshooting guide for more information.
RCPH11TLB007FAL 1
47365539 08/07/2012
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1021-Fuel temperature above normal

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTE: See engine repair manual for electrical schematic information.
Context:
Fuel temperature is greater than 82 °C (180 °F) for a period greater than 5 seconds. The Instrument Cluster will
illuminate the amber warning light while the is active fault.
Cause:
Fuel temperature is greater than 82 °C (180 °F) for a period greater than 5 seconds.
Solution:
played on the Instrument Cluster to warn the operator of a high fuel temperature warning. Refer to the engine
RCPH11TLB007FAL 1
47365539 08/07/2012
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1022-Water in fuel
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster has detected excess water in the fuel system. The Instrument Cluster will illuminate the amber
warning light while the is active fault.
Cause:
Fault Code 1022 is a CAN Data Link message from the ECU to the Instrument Cluster. This fault code is displayed
on the Instrument Cluster to warn the operator that the ECU has detected excess water in the fuel system. Refer to
Solution:
1. Drain the fuel filter of excess water.
RCPH11TLB007FAL 1
47365539 08/07/2012
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1023-Foot throttle supply voltage too high, over 5.2 volts for 5
seconds
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster detects a voltage greater than 5.2 V on the throttle 5 volt supply line (connector X-29, pin 18).
The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the next
system power up following the event.
Cause:
The Instrument Cluster detects a voltage greater than 5.2 V on the throttle 5 volt supply line (connector X-29, pin 18).
1. Throttle supply wire shorted to battery.

2. Wiring open circuit.
3. Failed Instrument Cluster.
Solution:
1. Verify that the fault code is still active. Cycle the key switch power. Refer to 0000 - Retrieving fault codes,
Backhoes.
A. OK – Fault code 1023 is not recorded again. OK to return the machine to service.
B. NOT OK – Fault is recorded again. Go to 2.

2. Check wiring to sensor
RCPH11TLB052FAL 1
Schematic legend
(1) Inspect the wiring from the Instrument Cluster to the foot throttle. The wires should be free of damage,
abrasion, corrosion and incorrect attachment.
47365539 08/07/2012
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A. OK — The wiring is free of damage, abrasion, corrosion and incorrect attachment. Go to Step 3.
B. NOT OK — The wiring is damaged or corroded. Repair as required. Go to Step 1 to confirm elimination
of fault code.
3. Measure the voltage at the foot throttle connector.
BD08E027-01 2
(1) Foot Throttle connector

(2) Foot Throttle sensor
(1) Disconnect the foot throttle sensor. Turn the key switch "On". Measure the voltage from pin C to pin B. The
voltage should be approximately 5 V.
A. OK — The voltage is between 4.8 V and 5.2 V. There is an intermittent condition in the wiring to the
Instrument Cluster. Inspect the wiring and connectors for damage. Repair as required. Go to 1 to confirm
B. NOT OK — The voltage is greater than 5.2 V. Go to Step 4.

4. Measure the voltage at the instrument cluster.
BD08E042-01 3

(1) Turn the key switch "Off." Remove wire 18 from connector X-29. Insert a test wire into pin 18.
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RCPH11TLB058FAL 4
Schematic legend
(2) Turn the key switch "On" and measure the voltage at pin 18. The voltage should be approximately 5 V.
A. OK — The voltage is 5 V. There is a problem in the wiring harness from the Instrument Cluster to the foot
throttle. Repair or replace the harness as required. Go to 1 to confirm elimination of fault.
B. NOT OK — The voltage is greater than 5.2 V. There is a problem in the Instrument Cluster. Temporarily
replace the Instrument Cluster and retest. Go to 1 to confirm elimination of fault.
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1024-Foot throttle supply voltage too low, under 4.8 volts for 5
seconds
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster detects a voltage less than 4.8 volts on the throttle 5 volt supply line (connector X-29, pin 18).
Cause:
The Instrument Cluster detects a voltage less than 4.8 volts on the throttle 5 volt supply line (connector X-29, pin 18).
1. Throttle supply wire shorted to minus battery or chassis ground.

2. Failed Throttle Sensor
3. Failed Instrument Cluster
Solution:
Backhoes.
A. OK – Fault code 1024 is not recorded again. OK to return the machine to service.
B. NOT OK – Fault is recorded again. Go to Step 2.

2. Inspect wiring to sensor
RCPH10TLB048FAM 1
Schematic legend
(1) Inspect the wiring from the Instrument Cluster to the foot throttle. The wires should be free of damage,
abrasion, corrosion and incorrect attachment.
47365539 08/07/2012
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A. OK — The wiring is free of damage, abrasion, corrosion and incorrect attachment. Go to Step 3.
B. NOT OK — The wiring is damaged or corroded. Repair as required. If the fault code is active after the
repair, go to Step 3.
3. Measure the voltage at the foot throttle connector.
BD08E027-01 2
(1) Foot Throttle connector

(2) Foot Throttle sensor
(1) Disconnect the foot throttle sensor. Turn the key switch "On". Measure the voltage from pin C to pin B. The
voltage should be approximately 5 volts.
A. OK — The voltage is between 4.8 and 5.2 volts. There is an intermittent condition in the wiring to the
Instrument Cluster. Inspect the wiring and connectors for damage. Repair as required. Go to 1 to confirm
B. NOT OK — The voltage is less than 4.8 volts. Go to Step 4.

BD08E042-01 3

(1) Turn the key switch "Off." Remove wire 18 from connector X-29. Insert a test wire into pin 18.
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RCPH11TLB058FAL 4
Schematic legend
(2) Turn the key switch "On" and measure the voltage from pin 18 to X-29 pin 26 (Ground or chassis ground).
The voltage should be approximately 5 volts.
A. OK — The voltage is 5 volts. There is a problem in the wiring harness from the Instrument Cluster to the
foot throttle. Replace or repair the harness. Go to 1 to confirm elimination of fault.
B. NOT OK — The voltage is less than 4.8 volts. There is a problem in the Instrument Cluster. Replace the
Instrument Cluster. Go to 1 to confirm elimination of fault.
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1025-Foot throttle sensor voltage over 5.3 volts for 5 seconds

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster measures a foot throttle signal greater than 5.3 volts for a period greater than 5 seconds. The
Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the next system
power up following the event.
Cause:
The Instrument Cluster measures a foot throttle signal greater than 5.3 volts for a period greater than 5 seconds.
1. Faulty wiring harness. Wiring or circuits shorted to positive battery.

2. Faulty reading from sensor.
Solution:
occurrence.

BD08E027-01 1

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too high, over 5.2 volts for 5 seconds (55.525). OR the voltage is less than 4.8 volts, go to procedure
RCPH10TLB017GAM 2

This step is used to monitor the foot throttle signal. The sensor must be connected and active in order to con-
tinue. The dealer must build a breakout harness as shown below.
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RCPH11TLB052FAL 3
Schematic legend
B).
A. OK — The voltage changed from approximately 0.5 volts to 4.2 volts. Go to Step 4.
B. NOT OK — The voltage did not change from 0.55 volts to 4.2 volts as the throttle moved from low idle
to WOT or the voltage was greater than 4.75 volts at WOT. Temporarily replace the sensor and retest.
Return to step 1 to confirm elimination of fault.
WOT or the voltage was greater than 4.75 volts at WOT. There is a problem in the throttle signal wire from
47365539 08/07/2012
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1026-Foot throttle sensor voltage under 200 mV for 5 seconds

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster measures a foot throttle signal less than 200mV (0.2 volts). The Instrument Cluster will illu-
minate the Warning Lamp and will sound the alarm for one second on the next system power up following the
event.
Cause:
The Instrument Cluster measures a foot throttle signal less than 200mV (0.2 volts).
1. Connectors not mated fully, pins not pushed into connector fully, bent pin or broken wire at rear of connector.
Connector pins corroded or dirty.
2. Faulty wiring harness. Wiring or circuits shorted to negative battery
Solution:
occurrence.

BD08E027-01 1

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too high, over 5.2 volts for 5 seconds (55.525). OR the voltage is less than 4.8 volts, go to procedure
RCPH10TLB017GAM 2

This step is used to monitor the foot throttle signal. The sensor must be connected and active in order to con-
tinue. The dealer must build a breakout harness as shown below.
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RCPH10TLB048FAM 3
Schematic legend
(1) Connect the breakout Tee and measure the voltage from pin A to pin B (or slide Back Probes into pin A and
B).
WOT or the voltage was less than 0.5 volts at low idle. Temporarily replace the sensor and retest. Return
the sensor to the Instrument Cluster. Repair or replace the wire as required. Return to step 1 to confirm
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1032-Hand throttle supply voltage too low, under 4.8 volts for 5
seconds
580N Power Shuttle, 580N T4, 580SN Power Shuttle, 580SN T4, 580SN WT Power Shuttle, 580SN WT T4, 590SN Power Shuttle, 590SN T4
Context:
The Instrument Cluster detects a voltage less than 4.8 volts on the hand throttle 5 volt supply line (connector X-29,
pin 19). The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the
next system power up following the event.
Cause:
The Instrument Cluster detects a voltage less than 4.8 volts on the hand throttle 5 volt supply line (connector X-29,
pin 19).
1. Throttle supply wire shorted to minus battery or chassis ground.

2. Failed Throttle sensor.
Solution:
Backhoes.

BD08E041-01 1
(1) Location of hand throttle

(2) Hand throttle connector
(1) Inspect the Instrument Cluster and the Hand Throttle connections. All connections should be secure and
tight and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster to the Hand Throttle. Verify that the harness is free of
damage, corrosion, abrasion and incorrect attachment.
3. Measure the voltage at the hand throttle connector.
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RCPH11TLB059FAL 2
Instrument Cluster Description Wire ID

X-029 connector
17 Throttle Signal 2171 YE
19 +5V Supply to throttle 2191 PK
21 Sensor Ground 2211 GN
Schematic legend
(1) Hand Throttle (3) Dealer supplied breakout T
(1) Disconnect the hand throttle sensor.
(2) Turn the key switch ON.
(3) Measure the voltage from pin A to pin C. The voltage should be approximately 5 volts.
A. OK — The voltage is between 4.8 and 5.2 volts. Replace the hand throttle and retest. Go to Step 1 to
B. NOT OK — The voltage is less than 4.8 volts. Go to Step 4.

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BD08E042-01 3

(1) Turn the key switch OFF. Remove wire 19 from connector X-29. Insert a test wire into pin 19.
RCPH10TLB036GAM 4
Schematic legend
(1) Hand Throttle (5) Remove existing wire from the Instrument
Cluster connector.
(2) Instrument Cluster (6) Insert a jumper wire.
(3) Breakout Harness (7) Existing Wire Harness
(4) Digital Voltmeter
(3) Measure the voltage from X-29 pin 19 to X-29 pin 21 (Ground or chassis ground). The voltage should be
approximately 5 volts.
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A. OK — The voltage is between 4.8 and 5.2 volts. There is a problem in the wiring harness from the Instru-
ment Cluster to the foot throttle. Replace or repair the harness as required. Go to 1 to confirm elimination
of fault.
B. NOT OK — The voltage is less than 4.8 volts. There is a problem in the Instrument Cluster. Temporarily
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1033-Hand throttle sensor voltage over 5.3 volts for 5 seconds

Context:
The Instrument Cluster detects a voltage greater than 5.3 volts on the hand throttle 5 volt supply line (connector X-29,
pin 19).The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the
Cause:
The Instrument Cluster detects a voltage greater than 5.3 volts on the hand throttle 5 volt supply line (connector X-29,
pin 19).
1. Throttle supply wire has an open circuit or is shorted to battery supply or another voltage source.
Solution:
Backhoes.

BD08E041-01 1

(1) Inspect the Instrument Cluster and the Hand Throttle connections. All connections should be secure and
damage, corrosion, abrasion or incorrect attachment.
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RCPH11TLB059FAL 2

X-029 connector
Schematic legend
A. OK — The voltage is between 4.8 and 5.2 volts. Temporarily replace the hand throttle and retest. Go to
B. NOT OK — The voltage is greater than 5.2 volts. Go to Step 4.

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BD08E042-01 3

(1) Turn the key switch OFF. Remove wire 19 from connector X-29. Insert a test wire into pin 19.
RCPH10TLB036GAM 4
Schematic legend
(1) Hand Throttle (5) Remove existing wire from the Instrument
Cluster connector.
(2) Instrument Cluster (6) Insert a jumper wire.
(3) Dealer Supplied Breakout Harness (7) Existing Wire Harness
(4) Digital Voltmeter
(3) Measure the voltage from X-29 pin 19 to X-29 pin 21 (Ground or chassis ground). The voltage should be
approximately 5 volts.
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A. OK — The voltage is between 4.8 and 5.2 volts. There is a problem in the wiring harness from the Instru-
ment Cluster to the foot throttle. Replace or repair the harness as required. Go to 1 to confirm elimination
of fault.
B. NOT OK — The voltage is less than 4.8 volts. There is a problem in the Instrument Cluster. Temporarily
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1034-Hand throttle sensor voltage under 200 mV for 5 seconds

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster detects a throttle signal less than 0.2 volts on the hand throttle signal line (connector X-29,
Cause:
pin 17).
1. Hand throttle signal wire is shorted to chassis ground.

Solution:
Backhoes.

BD08E041-01 1

(1) Inspect the Instrument Cluster and the Hand Throttle connections. All connections should be secure, tight,
free of corrosion, abrasion and damage.
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RCPH11TLB059FAL 2

X-029 connector
Schematic legend
(2) Disconnect the throttle sensor from the harness. Disconnect connector X-029 from the Instrument Cluster.
(4) Measure the resistance from X-029 pin 17 to pin B of the throttle connector. The resistance should be less
than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK — The resistance measurement from step 3 is greater than 20,000 ohms and the resistance measure-
ment from step 4 is less than 10 ohms. Go to Step 3.
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B. NOT OK — The resistance measurement from step (3) is less than 20,000 ohms. There is a short circuit
to chassis ground. Repair or replace the harness as required. Go to Step 3 to confirm elimination of the
fault.
C. NOT OK — The resistance measurement from step (4) is greater than 10 ohms. There is an open circuit
in the throttle signal wire. Repair or replace the harness as required. Go to Step 3 to confirm elimination
of the fault.
RCPH10TLB053FAM 3

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RCPH10TLB050FAM 4
Schematic legend
(1) Hand Throttle (3) Breakout Tee
(1) Connect the breakout Tee and measure the voltage from pin A to pin B (or slide Back Probes into pins A and
B).
A. OK — The voltage changed from 0.5 volts to 4.2 volts. Go to Step 4.
WOT or the voltage was less than 0.5 volts at low idle. Replace the sensor. Return to step 1 to confirm
A. OK — The voltage changed from 0.5 volts to 4.2 volts. Temporarily replace the Instrument Cluster. Go to
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1035-Hand throttle sensor signal above 95% of input for 5 seconds

Context:
The Instrument Cluster detects a throttle signal greater than 4.75 volts on the hand throttle signal line (connector X-29,
Cause:
The Instrument Cluster detects a throttle signal greater than 4.75 volts on the hand throttle signal line (connector X-29,
pin 17).
1. Hand throttle signal wire is shorted to another voltage source or there is an open circuit in the wire or connec-
tions.
Solution:
Backhoes.

BD08E041-01 1

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RCPH11TLB060FAL 2

X-029 connector
17 Throttle Signal 2171 YE 20GA
19 +5V Supply to throttle 2191 PK 20GA
21 Sensor Ground 2211 GN 20GA
Schematic legend
(1) Hand Throttle (2) Instrument Cluster
(3) Measure the resistance from X-029 pin 17 to battery supply. The resistance should be greater than 20,000
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to battery supply. Repair or replace the harness as required. Go to Step 3 to confirm elimination of the
fault.
of the fault.
RCPH10TLB053FAM 3

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RCPH10TLB050FAM 4
Schematic legend
(1) Hand Throttle (3) Breakout Tee
(1) Connect the break out Tee and measure the voltage from pin A to pin B (or slide Back Probes into pins A
and B).
WOT or the voltage was less than 0.5 volts at low idle. Temporarily replace the sensor and retest. Return
(4) Turn the key switch ON, engine OFF. Measure the voltage from the removed wire, pin 17 to X-29 pin 21
(Ground). Move the throttle from low idle to WOT (wide open throttle). The voltage should change from approx-
imately 0.55 volts at low idle to 4.2 volts at WOT.
A. OK — The voltage changed from 0.5 volts to 4.2 volts. Temporarily replace the Instrument Cluster and
retest. Go to Step 1 to confirm elimination of the fault.
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1036-Hand throttle sensor signal below 5% of input for 5 seconds

Context:
pin 17).The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the
Cause:
pin 17).

Solution:
Backhoes.

BD08E041-01 1

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RCPH11TLB060FAL 2

X-029 connector
Schematic legend
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fault.
of the fault.
RCPH10TLB053FAM 3

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RCPH10TLB050FAM 4
Schematic legend
B).
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1037-Hand throttle sensor out of range

Context:
Cause:
pin 17).

2. Hand throttle signal wire is shorted to battery supply or another voltage source.
3. Open circuit in the Hand throttle signal wire.
Solution:
Backhoes.

BD08E041-01 1

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RCPH11TLB060FAL 2

X-029 connector
Schematic legend
(4) Measure the resistance from X-029 pin 17 to battery. The resistance should be greater than 20,000 ohms.
Wiggle the harness during measurement to reveal an intermittent condition.
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B. NOT OK — The resistance measurements from step (3) or (4) is less than 20,000 ohms. There is a short
circuit in the harness. Repair or replace the harness as required. Go to Step 3 to confirm elimination of
the fault.
of the fault.
RCPH10TLB053FAM 3

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RCPH10TLB050FAM 4
Schematic legend
(1) Connect the break out Tee and measure the voltage from pin A to pin B (or slide Back Probes into pins A
and B).
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1039-Hand throttle sensor voltage under 200 mV for 5 seconds

Context:
Cause:
pin 17).

Solution:
Backhoes.

BD08E041-01 1

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RCPH11TLB060FAL 2

X-029 connector
Schematic legend
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fault.
of the fault.
RCPH10TLB053FAM 3

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RCPH10TLB050FAM 4
Schematic legend
B).
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1040-Engine RPM over 2750 for 5 seconds

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
The Instrument Cluster has detected an engine speed greater than 2750 RPM for a period greater than 5 seconds.
The Warning Lamp will illuminate Amber and the LCD backlight will change from the normal backlight to Amber.
The Instrument Cluster will sound the alarm for one second upon activation per key cycle.
Solution:
1. Fault Code 1040 is displayed on the Instrument Cluster to warn the operator that the engine speed has exceeded
2750 RPM.
RCPH11TLB007FAL 1
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1041-Engine RPM over 3000 for 5 seconds

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTICE: Always stop the machine and shut down the engine whenever the Danger lamp illuminates.
Cause:
The Instrument Cluster has detected an engine speed greater than 3000 RPM for a period greater than 5 seconds.
The Danger Lamp will illuminate Red and the LCD backlight will change from the normal backlight to Red. The
Instrument Cluster will sound the alarm continuously.
Solution:
1. Stop the engine.

2. Fault Code 1041 is displayed on the Instrument Cluster to warn the operator that the engine speed has exceeded
3000 RPM. Stop the engine.
RCPH11TLB007FAL 1
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1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster has detected the fuel sender resistance below 2 ohms for a period greater than 2 seconds.
Cause:
The Instrument Cluster has detected the fuel sender resistance below 2 ohms for a period greater than 2 seconds.
1. Wiring or circuits shorted to minus battery or chassis ground.

2. Faulty fuel level sensor.
Solution:
rence.

RCPH10TLB081AAM 1
(1) Fuel level sensor

(2) Fuel level sensor connector - X-063
(3) Connector X-001/X-051
(1) Inspect the Instrument Cluster and the Fuel Level Sender connections. All connections should be secure,
tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster to the Fuel Level Sender. Verify that the harness is free of
47365539 08/07/2012
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3. Measure the resistance of the fuel level signal to chassis ground.
(1) Disconnect connector X-63.
RCPH11TLB051FAL 2
Schematic legend
(2) Measure the resistance from X-63, pin A (Sensor side) to chassis ground. Refer to the fuel tank level. The
resistance reading should approximately equal the value from the table.
Level Length Resistance

1º Full 0.0 to 55.2 27.25 Ω ± 1.75 Ω
2º 55.2 to 141.0 47.5 Ω ± 2.0 Ω
3º 141.0 to 200.0 74.25 Ω ± 2.25 Ω
4º 200.0 to 228.0 84.5 Ω ± 2.5 Ω
5º 228.0 to 255.0 94.5 Ω ± 2.5 Ω
6º 255.0 to 282.0 104.5 Ω ± 2.5 Ω
7º 282.0 to 305.5 112.75 Ω ± 2.75 Ω
8º 1/2 tank 305.5 to 325.5 121.0 Ω ± 3.0 Ω
9º 325.5 to 346.0 129.25 Ω ± 2.75 Ω
10º 346.0 to 365.5 139.25 Ω ± 3.25 Ω
11º 365.5 to 385.0 149.25 Ω ± 3.25 Ω
12º 385.0 to 395.0 169.25 Ω ± 3.25 Ω
13º 395.0 to 405.0 189.25 Ω ± 3.75 Ω
14º 405.0 to 416.0 216.25 Ω ± 3.75 Ω
15º Empty 416.0 to 442.0 249.25 Ω ± 4.25 Ω
Resistance values are measured from the fuel level sensor connector X-063, pins A and B. If resistance mea-
surements are taken from connector X-051 and X-001 or from the Instrument Cluster, add 22 ohms to the
value.
A. OK - The resistance measurements were within tolerances. Go to Step 4.
B. NOT OK - The resistance values did not match the values from the table or the resistance was less than
25 ohms. Replace the sensor. Go to Step 1 to confirm elimination of the fault code.
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4. Measure the resistance at the fuel level sensor.
(1). Tilt the cab and remove the fuel level sender from the tank.
(2). Disconnect the harness from the sender.
(3). Move the fuel level float from the low to high position while measuring the resistance of the sender. The
resistance should change linearly from approximately 27 Ω at the full tank position to approximately 250 Ω at
the empty tank position. The resistance should change linearly without any fluctuations to a higher or lower
resistance.
A. OK - The resistance measurements from the sensor are within specifications. Go to Step 5.
B. NOT OK - The resistance readings from the sensor are not steady or the values are not accurate. Tem-
porarily replace sensor and retest. Return to Step 1 to confirm elimination of fault.
5. Check fuel level wiring.
(1). Measure the resistance from G021-BK (X 63 pin B) to ground. The resistance should be less than 10 ohms.
(2). Measure the resistance from 36F1-YE (X-063 pin A) to Instrument Cluster connector X-29, pin 13. The
resistance should be approximately 22 ohms. Wiggle the harness during measurement to reveal an intermittent
condition.
A. OK - The resistance measurements from the sensor were within specifications. Temporarily replace the
B. NOT OK - The resistance readings were not with the limits defined in the step. Repair or replace the
harness as required. Return to Step 1 to confirm elimination of fault.
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1045-Fuel level sensor open circuit

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster has detected an open circuit in the fuel sender signal. The Instrument Cluster will illuminate
the Warning Lamp and will sound the alarm for one second on the next system power up following the event.
Cause:
The Instrument Cluster has detected an open circuit in the fuel sender signal.
1. Open circuit in the fuel level sender signal wire.

2. Faulty fuel level sensor.
Solution:
rence.

RCPH10TLB081AAM 1
(1) Fuel level sensor

(2) Fuel level sensor connector - X-063
(3) Connector X-001/X-051
(1) Inspect the Instrument Cluster and the Fuel Level Sender connections. All connections should be secure,
(2) Inspect the harness from the Instrument Cluster to the Fuel Level Sender. Verify that the harness is free of
47365539 08/07/2012
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3. Measure the resistance of the fuel level signal wire to chassis ground.
(1) Disconnect connector X-63.
RCPH11TLB051FAL 2
Schematic legend
(2) Measure the resistance from X-63, pin A (Sensor side) to chassis ground. Refer to the fuel tank level. The
resistance reading should approximately equal the value from the table.
Level Length Resistance

1º Full 0.0 to 55.2 27.25 Ω ± 1.75 Ω
2º 55.2 to 141.0 47.5 Ω ± 2.0 Ω
3º 141.0 to 200.0 74.25 Ω ± 2.25 Ω
4º 200.0 to 228.0 84.5 Ω ± 2.5 Ω
5º 228.0 to 255.0 94.5 Ω ± 2.5 Ω
6º 255.0 to 282.0 104.5 Ω ± 2.5 Ω
7º 282.0 to 305.5 112.75 Ω ± 2.75 Ω
8º 1/2 tank 305.5 to 325.5 121.0 Ω ± 3.0 Ω
9º 325.5 to 346.0 129.25 Ω ± 2.75 Ω
10º 346.0 to 365.5 139.25 Ω ± 3.25 Ω
11º 365.5 to 385.0 149.25 Ω ± 3.25 Ω
12º 385.0 to 395.0 169.25 Ω ± 3.25 Ω
13º 395.0 to 405.0 189.25 Ω ± 3.75 Ω
14º 405.0 to 416.0 216.25 Ω ± 3.75 Ω
15º Empty 416.0 to 442.0 249.25 Ω ± 4.25 Ω
Resistance values are measured from the fuel level sensor connector X-063, pins A and B. If resistance mea-
surements are taken from connector X-051 and X-001 or from the Instrument Cluster, add 22 ohms to the
value.
A. OK - The resistance measurements were within tolerances. Go to Step 4.
B. NOT OK - The resistance values did not match the values from the table or the resistance was less than
25 ohms. Temporarily replace the sensor and retest. Go to Step 1 to confirm elimination of the fault code.
4. Measure the resistance at the fuel level sensor.
(1). Tilt the cab and remove the fuel level sender from the tank.
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(2). Disconnect the harness from the sender.
(3). Move the fuel level float from the low to high position while measuring the resistance across the sender.
The resistance should change linearly from approximately 27 Ω at the full tank position to approximately 250 Ω
at the empty tank position. The resistance should change linearly without any fluctuations to a higher or lower
resistance.
A. OK - The resistance measurements from the sensor were within specifications. Go to Step 5.
B. NOT OK - The resistance readings from the sensor were not steady or the values were not accurate.
Temporarily replace sensor and retest. Return to Step 1 to confirm elimination of fault.
5. Check fuel level wiring.
(1). Measure the resistance from G021-BK (X 63 pin B) to ground. The resistance should be less than 10 ohms.
(2). Measure the resistance from 36F1-YE (X-063 pin A) to Instrument Cluster connector X-29, pin 13. The
resistance should be approximately 22 ohms. Wiggle the harness during measurement to reveal an intermittent
condition.
(3). Measure the resistance from 36F1-YE (X 63 pin A) to ground (engine block). The resistance should be
greater than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - The resistance measurements from the sensor were within specifications. Temporarily replace the
B. NOT OK - The resistance readings were not with the limits defined in the step. Repair or replace the
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1047-Transmission temperature sensor below 3.0 ohms for 5

seconds
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Instrument Cluster measures a resistance less than 3 ohms for a period greater than 5 seconds. The Instrument
Cluster will illuminate the Warning Lamp and will sound the alarm for one second on the next system power up
following the event.
Cause:
The Instrument Cluster measures a resistance less than 3 ohms for a period greater than 5 seconds.
1. Wiring or circuits shorted to minus battery or chassis ground.

3. Faulty reading from Instrument Cluster.
Solution:
rence.

RCPH10TLB082AAM 1
(1) Transmission temperature sensor, connected to Instrument Cluster

(2) Transmission temperature sensor, connected to ECU
(1) Inspect the Instrument Cluster and the Transmission Temperature Sensor connections. All connections
should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Instrument Cluster to the Transmission Temperature Sensor. Verify that the
harness is free of damage, corrosion, abrasion or incorrect attachment.
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3. Measure the sensor open circuit resistance.
RCPH11TLB051FAL 2

X-029 connector
14 Transmission Temperature Signal 32T2 YE 20GA
Schematic legend
(1) Disconnect the terminal connector from the transmission temperature sender.
(2) Measure the resistance from the Transmission Temp Sensor to chassis ground.
Temperature Resistance in ohms. Measured from the sensor connection to chassis

ground
110 °C (230 °F) 130 Ω
105 °C (221 °F) 151 Ω
100 °C (212 °F) 175 Ω
95 °C (203 °F) 202 Ω
92 °C (198 °F) 223 Ω
88 °C (190 °F) 258 Ω
85 °C (185 °F) 280 Ω
81 °C (178 °F) 323 Ω
78 °C (172 °F) 358 Ω
74 °C (165 °F) 412 Ω
68 °C (154 °F) 511 Ω
16 °C (61 °F) 4250 Ω
A. OK – The resistance measurements are within the specifications in the table. Go to Step 4.
B. NOT OK – The resistance measurements are not within range or the measurement is less than 3 ohms.
Replace transmission temperature sender. Return to Step 1 to confirm elimination of fault.
4. (1) Measure the resistance of the signal wire to chassis ground.
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55.DTC / 113
(2) Disconnect connector from transmission temperature sender.
(3) Disconnect the Instrument Cluster connector X-29.
BD08E042-01 3

(4) Measure the resistance from X-29, pin 14 to X-29 pin 26. Wiggle the harness during measurement to reveal
an intermittent condition. The resistance should be greater than 20,000 ohms.
(5) Measure the resistance from X-29, pin 14 to chassis ground. Wiggle the harness during measurement to
reveal an intermittent condition. The resistance should be greater than 20,000 ohms.
A. OK – The resistance measurements are greater than 20,000 ohms. Temporarily replace the Instrument
Cluster and retest. Return to Step 1 to confirm elimination of fault.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit in the signal wire. Repair or
replace the wire as required. Go to Step 1 to confirm elimination of fault.
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1050-Alternator L+ terminal under 1.5 volts for 5 seconds

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTE: The battery must be at full charge, and all connections must be clean and tight before testing the electrical
system.
Context:
The Instrument Cluster measured a voltage less than 1.5 V for a period greater than 5 seconds on connector X-29,
pin 24. The Instrument Cluster will illuminate the battery warning symbol when it detects a problem in the battery
charging system. The Instrument Cluster will illuminate the Warning Lamp and will sound the alarm for one
second on the next system power up following the event.
Cause:
The Instrument Cluster measured a voltage less than 1.5 V for a period greater than 5 seconds.
2. Wiring or circuits open.
3. Connector pins corroded or dirty.
4. Alternator output voltage is less than 11 V.
5. Faulty reading from Instrument Cluster.
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes
rence.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 115
A. Fault is not recorded again. OK to return the machine to service.
B. Fault code 1050 is recorded again. Go to Step 2.

(1) Inspect the alternator and battery connections. All connections should be secure, tight, free of corrosion,
abrasion and damage.
(2) Inspect the harness from the alternator and battery to the Instrument Cluster. Verify that the harness is free
of damage, corrosion, abrasion or incorrect attachment.
A. All connections are secure and the harness is free of damage. Go to Step 3.
B. The connectors or the harness has damage. Repair or replace the harness or connectors as required.
Return to Step1 to confirm elimination of the fault.
3. Test the alternator output
(1) Start the engine. Set engine speed to low idle.
(2) Measure the voltage at the Alternator output. The voltage should be approximately 14.5 V.
RAIL11TLB0004AA 2
(1) Alternator (2) Connector X-083
A. The alternator voltage is less than 11 V. Replace the alternator. Return to Step 1 to confirm elimination of
fault.
B. The alternator output voltage is approximately 14.5 V. Go to Step 4.

RCPH11TLB056FAL 3
47365539 08/07/2012
55.DTC / 116
Schematic Legend
YE
(1) Disconnect the Instrument Cluster Connector 2 ( X 29). Inspect pins, wiring and connectors for damage,
abrasion, corrosion or incorrect attachment.
(2) Measure the voltage on pin X-29 pin 24 to X-29 pin 26. The voltage should be approximately 14.5 V. Wiggle
the harness during measurement to reveal an intermittent condition.
A. The measured voltage is approximately 14.5 V. Temporarily replace the Instrument Cluster and retest. Go
to Step 1 to confirm elimination of the fault code.
B. The measured voltage is less than 11 V. Replace the alternator. Return to Step 1 to confirm elimination
of fault.
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1051-1059- Timeout of CAN message

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
CAN Data Link communications between the Instrument Cluster and the ECU have been lost. The Instrument Cluster
did not receive the EEC1 message from the ECU. This fault code may be displayed with other CAN Data Link fault
messages. The Instrument Cluster will illuminate the Danger Lamp and will continually sound the audible
alarm. The Low Oil Pressure lamp will also turn on.
Cause:
The Instrument Cluster has stopped receiving CAN messages from the ECU. CAN Data Link communications be-
tween the Instrument Cluster and the ECU have been lost.
1. CAN data link wiring or circuits open.

2. CAN data link wiring or circuits shorted.
4. Faulty ECU
Solution:
Prior to clearing fault codes, write down all existing fault codes, number of occurrences, and engine hours at
last occurrence.
If three or more fault codes are active, 1051 through 1059, this is an indication of a problem in the CAN Data
Link circuit, continue with this procedure. If one or two CAN Data Link fault codes are active, this is an indication
of an intermittent connection in the CAN circuit. Check all wire and connector to verify they are secure and free
RCPH11TLB007FAL 1
(1) Use the Electronic Service Tool to verify that the CAN data link faults are ACTIVE.
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(2) To check for fault codes: Start and operate machine. Wiggle the harness to reveal an intermittent condition.
A. OK – CAN Data Link fault codes are not recorded again and are no longer ACTIVE. OK to return the
machine service.
B. NOT OK – CAN Data Link fault codes are present and ACTIVE. Go to Step 2.
2. Verify the harness is not damaged
(2) Verify the connections to the ECU, Instrument Cluster, diagnostic connector, Trax control (if installed) and
the optional Telematics unit are tight and secure.
(3) Verify the harness is free of damage, abrasion, corrosion and incorrect attachment from the ECU to the
Instrument Cluster. Verify all data link drops are free of damage, abrasion, corrosion and incorrect attachment.
RCPH11TLB034GAL 2
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(1) Switched battery to diagnostic port (5) CAN Bus to Instrument Cluster
CAN High X-029 pin 4
CAN Low X-029 pin 3
(2) Diagnostic Port X-002 (6) CAN Bus to ECU
CAN Low X-461 pin 25
(3) Diagnostic port minus battery connection (7) CAN Bus to Telematics (optional)
CAN High X-498 pin E
CAN Low X-498 pin D
(4) CAN Bus to Trax Control (8) Switched battery to Telematics (optional)
CAN High X-300 pin 27 Fuse F-001, 5 A
A. OK - The CAN Data Link harness is not damaged and all connections are secure. Go to Step 3.
B. NOT OK - The harness is damaged or the connectors are loose or damaged. Repair or replace the harness
as required. Go to Step 1 to confirm elimination of fault.
3. Measure the resistance through the CAN Data Link harness
(2) Measure the resistance between the Diagnostic Port connector, CAN 1 High and CAN 1 Low pins, pins C
and D. The resistance should be approximately 60 Ω. Wiggle the harness during measurement to reveal an
A. The resistance is between 54 Ω and 66 Ω. Go to Step 4.
B. The resistance is less than 50 Ω. Go to Step6.
C. The resistance is greater than 70 Ω. Go to Step 6.

4. Measure harness resistance to chassis ground and positive battery.
(2) Disconnect the Instrument Cluster connector, X-029. Disconnect all devices connected to the CAN Data
Link. Measure the resistance from pin 3 on connector X-029 to chassis ground. Measure the resistance from
pin 4 on connector X-029 to chassis ground. The resistance should be greater than 20,000 Ω. Wiggle the
(3) Measure the resistance from pin 3 on connector X-029 to positive battery ( X-029 pin 1). Measure the re-
sistance from pin 4 on connector X-029 to positive battery ( X-029 pin 1).The resistance should be greater than
20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
Circuit description Instrument Cluster connection Alternate Diagnostic Port connection

Switched Battery X-029 pin 1 X–002 pin B
Minus Battery X-029 pin 26 X–002 pin A
CAN High X-029 pin 4 X–002 pin C
CAN Low X-029 pin 3 X–002 pin D
A. OK - All resistance measurements are greater than 20,000 Ω. Verify the ECU is powered and operational.
Verify that all minus battery and chassis ground connetcions to the CAN Bus modules are clean and se-
cure. Return to Step 1.
B. NOT OK - The resistance is less than 20,000 Ω. There is a short circuit in the CAN Data Link. Temporarily
replace the CAN Data Link wires and retest. Repair or replace the harness as required. Go to Step 1 to
confirm elimination of the fault code.
5. Measure the resistance between the CAN High and CAN Low
(1) Turn the key switch OFF. Disconnect all modules on the CAN bus.
(2) Measure the resistance between CAN High (Diagnostic Connector pin C) and CAN Low (Diagnostic Con-
nector pin D)
47365539 08/07/2012
55.DTC / 120
A. The resistance is greater than 20,000 Ω. Connect each component to the CAN Bus one at a time. The
resistance should be greater than 60 Ω. Replace the module that drops the CAN Bus line resistance below
60 Ω. Go to Step 1 to confirm elimination of the fault.
B. NOT OK - The resistance is less than 56 Ω there is a short circuit between the CAN High and CAN Low
wires. Repair or replace the harness as required. Go to test Step 1 to confirm elimination of the fault.
6. Measure the resistance through the CAN Data Link circuit.
(1) Turn the key switch OFF. Disconnect all components connected to the CAN Bus.
(2) Fabricate a jumper 20 cm (8 in).
(3) Short the CAN Bus pins on the ECU together, X-461 pin 25 and X-461 pin 24.
(4) Measure the resistance across Diagnostic Port connector pins C and D. The resistance should be less than
10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
RCPH11TLB074FAL 3
(1) Digital volt meter set to measure resis- (5) CAN Bus to Instrument Cluster
tance CAN High X-029 pin 4
CAN Low X-029 pin 3
(3) Jumper wire installed between the CAN (7) CAN Bus to Telematics (optional)
High and CAN Low pins CAN High X-498 pin E
CAN Low X-498 pin D
(4) CAN Bus to Trax Control
(5) Measure the resistance across the Telematics connector pins E and D. The resistance should be less than
(6) Measure the resistance across the Trax connector X-300 pin 27 and X-300 pin 55. The resistance should
be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
(7) Measure the resistance across Instrument Cluster connector X-029 pin 4 and X-029 pin 3. The resistance
should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
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RCPH11TLB072FAL 4
CAN Low X-029 pin 3
High and CAN Low pins CAN High X-498 pin E
CAN Low X-498 pin D
A. All resistance measurements are less than 10 Ω. Temporarily replace the Instrument Cluster and retest.
B. A resistance measurement is greater than 20,000 Ω. There is an open circuit in the wiring to the ECM.
Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
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3006-Coolant Temperature Sensor - Signal Not Plausible

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) generated an error from a fault associated with the Coolant temp sensor. This error
could result from a signal out of range or a signal that is either erratic or intermittent. When the ECU determines
that the Coolant temp sensor temperature value is not valid, it will substitute another value to be used. In case of a
defective Coolant temp sensor during engine warm-up, a default coolant temperature value is derived from the ramp
of the currently logged sensor data. If an error would occur during normal engine operation, the oil temperature is
used as the default value. If the Oil temp / press sensor is defective, 85 °C (185 °F) is substituted as the default value.
Cause:
The Coolant temp sensor signal to the ECU is either erratic or intermittent.
1. Faulty Coolant temp sensor.

2. Faulty electrical wiring or intermittent connection between Coolant temp sensor and ECU.
3. Faulty ECU, supply voltages or grounds.
Solution:
1. Operation: Electrical Inspection.

Vehicle Status: Key Off Engine Off.
Remove Coolant temp sensor connector WTF and inspect housing body/latch, pins and wiring harness for dam-
age. Also, inspect connector portion of the Coolant temp sensor.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure a
good and sound electrical connection.
B. If no damage is determined, proceed to step 2.

2. Operation: Check Open Circuit Supply Voltage for Coolant temp sensor.
Vehicle Status: Key On Engine Off.
Remove connector WTF from Coolant temp sensor and check for voltage as outlined in the table below.
Test Type From To Expected Results

1. Voltage WTF (Pin 1) (+) WTF (Pin 2) (-) Approx. 5 volts (DC)
A. If 5 volts (DC) is present, proceed to step 4.
B. If 5 volts (DC) is not present, proceed to step 3.

3. Operation: Check for Faulty Wiring.
Vehicle status: Key Off Engine Off.
Remove and perform continuity tests between connectors WTF and 2 on engine sensor harness. Flex harness
during test to check for any intermittent operation. See test table below.
Important Note:
Check and verify that the Vehicle Status is correct. Potential ECU damage could result when removing main
ECU connectors if this is not followed.

1. Continuity WTF (Pin: 1) 2, (Pin: 15) Approx. 0 - 0.10 ohms
2. Continuity WTF, (Pin: 2) 2, (Pin: 26) Approx. 0 - 0.10 ohms
3. Short Circuit 2, (Pin: 15) 2, (Pin: 32) Open Circuit
47365539 08/07/2012
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A. If continuity/shorts test is successful, go to step 4.
B. If continuity/shorts test is unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. Operation: Coolant temp sensor Test
Remove WTF connector and test resistance of Coolant temp sensor using the table of resistance vs. temp.
below. Approximate the temperature when performing test. Coolant temp sensor failures are typically at the
extreme ends of the table or off the table entirely.
Coolant Temperature Resistance Value

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
A. If the resistance measurement does not approximately match the table, replace the sensor.
B. If the resistance measurement does approximately match the table, proceed to step 5.
5. Operation: Check for ECU Voltages and Ground Continuity.
Vehicle Status (when removing connector 1): Key Off Engine Off.
Vehicle Status (when performing test): Key On Engine Off.
Vehicle Status (when replacing connector 1): Key Off Engine Off.
Use product schematic for a reference, remove connector 1 from the ECU and check for 12 volts and continuity
at the appropriate pins defined in the test table below.
Important Note:
Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage could result when
removing and replacing main ECU connectors if this is not followed.

1. Voltage 1, (Pin 2, 3, 8, 9, 40) Ground (engine block) Approx. 12 volts
2. Continuity 1, (Pin 5, 6, 10, 11) Ground (engine block) Approx. 0 - 0.10 ohms
A. If the voltages and ground paths are correct and the Coolant temp sensor was not replaced on a prior
diagnostic of this type, replace the sensor.
B. If the voltages and ground paths are correct and the Coolant temp sensor was replaced on a prior diag-
nostic of this type, re-initialize the ECU as if it was blank (new) and load the appropriate data-set.
C. If the voltages and ground paths are correct and the ECU was re-initialized on a prior diagnostic of this
type, replace the ECU.
D. If the voltages and ground paths are not correct, refer to schematic and determine root cause of power or
continuity problem(s).
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3007-Coolant Temperature Signal - Signal Above Range Maximum

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) generated an error from a fault associated with the Coolant temperature sensor. This
error could result from a signal out of range or a signal that is either erratic or intermittent. When the ECU determines
that the Coolant temperature sensor temperature value is not valid, it will substitute another value to be used. In case
of a defective Coolant temperature sensor during engine warm-up, a default coolant temperature value is derived
from the ramp of the currently logged sensor data. If an error would occur during normal engine operation, the oil
temperature is used as the default value. If the Oil temperature / pressure sensor is defective, 85 °C (185 °F) is
substituted as the default value.
Cause:
The Coolant temperature sensor signal to the ECU is out of range of the upper threshold limit.
1. Faulty electrical wiring, short to high source or open circuit condition.

2. Faulty Coolant temperature sensor.
3. Faulty ECU.
Solution:
1. Verify the fault code is present and active.
A. If fault code is present and active, continue with 2.
B. If fault code is no longer present, continue with step 6.

2. Verify complete voltage supply circuit for the Coolant temperature sensor. Remove the connector WTF from
Coolant temperature sensor and check for voltage outlined in the table below.

1. Voltage Coolant temperature sen- Coolant temperature sen- Approx. 5 volts
sor connector WTF (Pin 1) sor connector WTF (Pin 2)
(+) (-)
A. If 5 volts is present, continue with step 4.
B. If 5 volts is not present, continue with step 3.

3. Check for faulty wiring. Remove and perform continuity tests between the Coolant temperature sensor and the
ECU engine connectors on the engine sensor harness. Flex harness during test to check for any intermittent
operation. See test table below.

1. Continuity Coolant temperature sen- ECU engine connector 2 Approx. 0 - 0.10 ohms
sor connector WTF (Pin: (Pin: 15)
1)
2. Continuity Coolant temperature sen- ECU engine connector 2 Approx. 0 - 0.10 ohms
sor connector WTF (Pin: (Pin: 26)
2)
3. Short Circuit ECU engine connector 2 ECU engine connector 2 Open Circuit
(Pin: 15) (Pin: 32)
4. Short Circuit ECU engine connector ECU engine connector 2 Open Circuit
2(Pin: 15) (Pin: 33)
5. Short Circuit ECU engine connector 2 ECU engine connector 2 Open Circuit
(Pin: 15) (Pin: 26)
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A. If continuity/short tests are successful, continue with step 4.
B. If continuity/short test are unsuccessful, find and repair the damaged section(s) of the wiring harness.
4. Verify proper Coolant temperature sensor operation. Remove Coolant temperature sensor connector WTF and
test resistance of Coolant temperature sensor using the table of resistance vs. temp. below. Approximate the
temperature when performing test. Coolant temperature sensor failures are typically at the extreme ends of the
table or off the table entirely.

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
B. If the resistance measurement does approximately match the table, continue with step 5.
5. Verify ECU ground and voltage supply. Use the product schematic for a reference, with the ignition switch OFF
remove ECU vehicle connector 1 from the ECU. Check for 12 volts with the ignition switch in the ON position,
and continuity at the appropriate pins defined in the test table below.

1. Voltage ECU vehicle connector 1 Ground (engine block) Approx. 12 volts
(Pin 2, 3, 8, 9, 40)
2. Continuity ECU vehicle connector 1 Ground (engine block) Approx. 0 - 0.10 ohms
(Pin 5, 6, 10, 11)
A. If the voltages and ground paths are correct and the ECU was re-initialized on a prior diagnostic of this
B. If the voltages and ground paths are not correct locate and repair the damaged section(s) of the wiring
harness.
6. Visually inspect the relevant harnesses and connectors for damage, bent or dislocated pins, corroded terminals
or broken wires. Verify that the connectors are fully installed. Flex the harnesses involved to reveal intermittent
breaks or shorts in the wiring concerned. Operate the machine while monitoring the Display.
A. If damage is found or other than normal display readings are indicated, repair the damage discovered
during the inspection or locate and repair the other than normal display condition and verify that the error
has been resolved.
B. If no damage or other than normal display readings are indicated, erase the fault code and continue oper-
ation.
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3008-Coolant Temperature Signal - Signal Below Range Minimum

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) generated an error from a fault associated with the Coolant temperature sensor. This
error could result from a signal out of range or a signal that is either erratic or intermittent. When the ECU determines
that the Coolant temperature sensor temperature value is not valid, it will substitute another value to be used. In case
of a defective Coolant temperature sensor during engine warm-up, a default coolant temperature value is derived
from the ramp of the currently logged sensor data. If an error would occur during normal engine operation, the oil
temperature is used as the default value. If the Oil temperature / pressure sensor is defective, 85 °C (185 °F) is
substituted as the default value.
Cause:
The Coolant temperature sensor signal to the ECU is out of range of the lower threshold limit.
1. Faulty electrical wiring, short to low source condition.

2. Faulty Coolant temperature sensor.
3. Faulty ECU.
Solution:
A. If fault code is present and active, continue with step 3.

2. Verify Coolant temperature sensor is working properly. Disconnect the Coolant temperature sensor, connector
WTF, and test resistance of Coolant temperature sensor using the table of resistance vs. temperature below.

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
B. If the resistance measurement does approximately match the table, continue with step 4.
3. Check for supply voltage from the ECU in the Coolant temperature sensor supply wiring. Remove the connector
from Coolant temperature sensor WTF and check for voltage between Coolant temperature sensor connector
WTF, pin 1 and ground. There should be 5 volts.
A. If 5 volts is present, continue with step 5.
B. If 5 volts is not present, continue with step 2.

4. Check the ECU output to the Coolant temperature sensor. With the ignition switch in the OFF position, remove
the Coolant temperature sensor connector WTF and the ECU engine connector 2 on engine sensor harness.
Turn the ignition switch to the ON position and check for voltage between ECU engine connector WTF, pin 15
and ground. There should be 5 volts.
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A. If 5 volts is present, locate a repair the open circuit condition between the ECU engine connector 2, pin
15 and the Coolant temperature sensor connector WTF, pin 1.
B. If 5 volts is not present, replace the ECU.

5. Verify the Coolant temperature sensor ground path. With the ignition switch in the OFF position, disconnect
ECU engine connector, 2, and check for continuity to ground from pin 26 of the ECU.
A. If there is continuity, locate and repair short to ground in Engine sensor harness between the ECU engine
connector 2 and the Coolant temperature sensor connector, WTF.
B. If there is not continuity, replace the ECU.

has been resolved.
B. If no damage or no other than normal display readings are indicated, erase the fault code and continue
operation.
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3010-Air intake temperature sensor signal above maximum range

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) generated an error from a fault associated with the Boost Pressure sensor. The Boost
Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related
to the temperature sensing function of the device. This error could result from a signal out of range or a signal that
is either erratic or intermittent. When the ECU determines that the Boost Pressure sensor value is not valid, it will
substitute a default value of 29.96 °C (86 °F).
Cause:
The Boost Pressure sensor signal to the ECU is out of range of the upper threshold limit.
1. Faulty electrical wiring or connection.

2. Faulty sensor.
3. Faulty ECU.
Solution:

Remove Boost Pressure sensor connector LDFT and inspect housing body/latch, pins and wiring harness for
damage. Also, inspect connector portion of the Boost Pressure sensor.
good and sound electrical connection. Replace Boost Pressure sensor if damaged.

2. Operation: Check Open Circuit Voltages for Boost Pressure sensor.
Remove connector LDFT from Boost Pressure sensor and check for voltages between connector pins outlined
in the table below.

1. Voltage LDFT (Pin 3) LDFT (Pin 1) Approx. 5 volts
3. Voltage LDFT (Pin 4) LDFT (Pin 1) Approx. 5.4 volts
A. If the voltage test sequence is successful, proceed to step 4.
B. If the voltage test sequence is not successful, proceed to step 3.

Remove and perform continuity/shorts tests between connectors LDFT and 2 on engine wiring harness. Flex
harness during test to check for any intermittent operation.
Important Note:
Test Type From: To: Expected Results

1. Continuity LDFT (Pin: 1) 2 (Pin: 25) Approx. 0 - 0.10 ohms
47365539 08/07/2012
55.DTC / 129

5. Shorts 2 (Pin: 36) 2 (Pin: 25, 34, 33) Open Circuit
6. Shorts 2 (Pin: 25) 2 (Pin: 34, 33) Open Circuit
7. Shorts 2 (Pin: 34) 2 (Pin: 33) Open Circuit
4. Operation: Boost Pressure sensor Test
Remove the Boost Pressure sensor connector LDFT and remove the sensor from the engine intake manifold.
Allow the sensor to cool to ambient temperature for several minutes, and then test sensor resistance across
pins 2 and 3, using the table of resistance vs. temperature below. Approximate the ambient air temperature
when performing the test.
Temperature Resistance Nominal Value Resistance Min/Max. Range

-40 °C (-40 °F) 48153 ohms 45301 - 51006 ohms
-35 °C (-31 °F) 35763 ohms 33703 - 37823 ohms
-30 °C (-22 °F) 26854 ohms 25350 - 28359 ohms
-25 °C (-13 °F) 20376 ohms 19265 - 21487 ohms
-20 °C (-4 °F) 15614 ohms 14785 - 16443 ohms
-15 °C (5 °F) 12078 ohms 11453 - 12702 ohms
-10 °C (14 °F) 9426 ohms 8951 - 9901 ohms
-5 °C (23 °F) 7419 ohms 7055 - 7783 ohms
0 °C (32 °F) 5887 ohms 5605 - 6168 ohms
5 °C (41 °F) 4707 ohms 4487 - 4926 ohms
10 °C (50 °F) 3791 ohms 3618 - 3964 ohms
15 °C (59 °F) 3075 ohms 2939 - 3211 ohms
20 °C (68 °F) 2511 ohms 2402 - 2619 ohms
25 °C (77 °F) 2063 ohms 1976 - 2150 ohms
30 °C (86 °F) 1715 ohms 1645 - 1786 ohms
35 °C (95 °F) 1432 ohms 1374 - 1490 ohms
40 °C (104 °F) 1199 ohms 1152 - 1247 ohms
45 °C (113 °F) 1009 ohms 970 - 1047 ohms
50 °C (122 °F) 851 ohms 819 - 883 ohms
55 °C (131 °F) 721 ohms 694 - 747 ohms
60 °C (140 °F) 612 ohms 590 - 634 ohms
65 °C (149 °F) 522 ohms 503 - 540 ohms
70 °C (158 °F) 446 ohms 431 - 462 ohms
75 °C (167 °F) 383 ohms 370 - 396 ohms
80 °C (176 °F) 329 ohms 319 - 340 ohms
85 °C (185 °F) 284 ohms 275 - 293 ohms
90 °C (194 °F) 246 ohms 238 - 254 ohms
95 °C (203 °F) 214 ohms 207 - 220 ohms
100 °C (212 °F) 186 ohms 180 - 192 ohms
105 °C (221 °F) 162 ohms 157 - 167 ohms
110 °C (230 °F) 142 ohms 138 - 147 ohms
115 °C (239 °F) 125 ohms 121 - 129 ohms
120 °C (248 °F) 110 ohms 106 - 113 ohms
125 °C (257 °F) 97 ohms 93 - 100 ohms
130 °C (266 °F) 85 ohms 83 - 88 ohms
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55.DTC / 130

Use product schematic for a reference, remove connector 1 from the ECU and check for voltage and continuity
Important Note:

1. Voltage 1 (Pin 2, 3, 8, 9, 40) Ground (engine block) Approx. 12 volts
2. Continuity 1 (Pin 5, 6, 10, 11) Ground (engine block) Approx. 0 - 0.10 ohms
A. If the voltages and ground paths are correct and the Boost Pressure sensor was not replaced on a prior
B. If the voltages and ground paths are correct and the Boost Pressure sensor was replaced on a prior diag-
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3011-Air intake temperature sensor signal below minimum range

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
to the temperature sensing function of the device. This error could result from a signal out of range or a signal that
is either erratic or intermittent. When the ECU determines that the Boost Pressure sensor value is not valid, it will
substitute a default value of 29.96 °C (86 °F).
Cause:
The Boost Pressure sensor signal to the ECU is out of range of the lower threshold limit.
1. Faulty sensor.
Solution:


Remove LDFT connector from Boost Pressure sensor and check for voltages (DC) between connector pins
outlined in the table below.


Remove and perform continuity/shorts tests between connectors on engine wiring harness. Flex harness during
test to check for any intermittent operation. See test table below.
Important Note:

1. Continuity LDFT 2 (Pin: 25) Approx. 0 - 0.10 ohms
47365539 08/07/2012
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4. Operation: Boost Pressure sensor Test
Remove the Boost Pressure sensor connector LDFT and remove the sensor from the engine intake manifold.
Allow the sensor to cool to ambient temperature for several minutes, and then test sensor resistance across
pins 2 and 3, using the table of resistance vs. temperature below. Approximate the ambient air temperature
when performing the test.
Temperature Resistance Nominal Value Resistance Min/Max. Range

-40 °C (-40 °F) 48153 ohms 45301 - 51006 ohms
-35 °C (-31 °F) 35763 ohms 33703 - 37823 ohms
-30 °C (-22 °F) 26854 ohms 25350 - 28359 ohms
-25 °C (-13 °F) 20376 ohms 19265 - 21487 ohms
-20 °C (-4 °F) 15614 ohms 14785 - 16443 ohms
-15 °C (5 °F) 12078 ohms 11453 - 12702 ohms
-10 °C (14 °F) 9426 ohms 8951 - 9901 ohms
-5 °C (23 °F) 7419 ohms 7055 - 7783 ohms
0 °C (32 °F) 5887 ohms 5605 - 6168 ohms
5 °C (41 °F) 4707 ohms 4487 - 4926 ohms
10 °C (50 °F) 3791 ohms 3618 - 3964 ohms
15 °C (59 °F) 3075 ohms 2939 - 3211 ohms
20 °C (68 °F) 2511 ohms 2402 - 2619 ohms
25 °C (77 °F) 2063 ohms 1976 - 2150 ohms
30 °C (86 °F) 1715 ohms 1645 - 1786 ohms
35 °C (95 °F) 1432 ohms 1374 - 1490 ohms
40 °C (104 °F) 1199 ohms 1152 - 1247 ohms
45 °C (113 °F) 1009 ohms 970 - 1047 ohms
50 °C (122 °F) 851 ohms 819 - 883 ohms
55 °C (131 °F) 721 ohms 694 - 747 ohms
60 °C (140 °F) 612 ohms 590 - 634 ohms
65 °C (149 °F) 522 ohms 503 - 540 ohms
70 °C (158 °F) 446 ohms 431 - 462 ohms
75 °C (167 °F) 383 ohms 370 - 396 ohms
80 °C (176 °F) 329 ohms 319 - 340 ohms
85 °C (185 °F) 284 ohms 275 - 293 ohms
90 °C (194 °F) 246 ohms 238 - 254 ohms
95 °C (203 °F) 214 ohms 207 - 220 ohms
100 °C (212 °F) 186 ohms 180 - 192 ohms
105 °C (221 °F) 162 ohms 157 - 167 ohms
110 °C (230 °F) 142 ohms 138 - 147 ohms
115 °C (239 °F) 125 ohms 121 - 129 ohms
120 °C (248 °F) 110 ohms 106 - 113 ohms
125 °C (257 °F) 97 ohms 93 - 100 ohms
130 °C (266 °F) 85 ohms 83 - 88 ohms
47365539 08/07/2012
55.DTC / 133

Use the schematic for a reference, remove 1 connector from the ECU and check for voltage and continuity at
the appropriate pins defined in the test table below.
Important Note:

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3015-Fuel Temperature Sensor - Signal Above Maximum

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) has detected a fault associated with Fuel temperature sensor. This error typically
results from a signal that is out of range. When the ECU determines that the Fuel temperature sensor temperature
value is invalid, it will substitute the current coolant temperature value, or in the case of a defective Coolant tempera-
ture sensor , the value 19.96 ° C (67.9 °F) will be substituted.
Cause:
The Fuel temperature sensor signal to the ECU is out of the range of the upper threshold limit.
1. Faulty Fuel temperature sensor.

2. Faulty electrical wiring or short to high source or open circuit condition.
Solution:
1. Verify this error code is still present and in an active state.
A. If the error is still present and active, continue with step 2.
B. If the error is no longer present or is in an inactive state, continue with step 6.

2. Ensure electrical integrity of the Fuel temperature sensor. Remove connector KTF from the Fuel temperature
sensor and use a multi-meter to check the resistance of the sensor. Use the table below to ensure proper sensor
resistance.
Fuel Temperature Resistance Value

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
A. If sensor resistance is within range leave connector KTF disconnected and continue with step 3.
B. If the sensor is out of range, replace the sensor.

3. Verify proper supply voltage to the sensor from the ECU. Measure voltage between connector KTF, pin 2 and
ground. There should be 5 V.
A. If there is 5 V, continue with step 5.
B. If there is greater than 5 V, continue with step 4.

4. Verify voltage output from ECU. Disconnect ECU engine connector, connector 3. Measure voltage between pin
24 on the ECU and ground. There should be 5 V.
A. If there is 5 V, there is a short to high source between ECU engine connector, connector 2, and the Fuel
temperature sensor connector, connector KTF. Locate and repair the shorted condition.
B. If there is greater than 5 V, there is a short to high source internal to the ECU, replace the ECU.
5. Check signal wire from Fuel temperature sensor to ECU. Measure voltage between the ECU engine connector,
connector 3, pin 35 and ground.
47365539 08/07/2012
55.DTC / 135
has been resolved.
ation.
47365539 08/07/2012
55.DTC / 136
3016-Fuel Temperature Sensor - Signal Below Range Minimum

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) has generated a fault associated with Fuel temperature sensor . This error typically
results from a signal that is out of range. When the ECU determines that the fuel temperature sensor temperature
value is invalid, it will substitute the current "Coolant Temperature" value, or in the case of a defective Coolant tem-
perature sensor , the value 19.96 °C (67.9 °F) will be substituted.
Cause:
The Fuel temperature sensor signal to the ECU is out of the range of the lower threshold limit.
1. Faulty Fuel temperature sensor .

2. Faulty electrical wiring or short to low source (ground).
Solution:

Remove Fuel temp sensor connector KTF and inspect housing body/latch, pins and wiring harness for damage
or corrosion. Also, inspect connector portion of the Fuel temp sensor.
A. If a problem is determined after careful inspection, repair wiring and/or replace connector parts to ensure
a good and sound electrical connection. Replace Fuel temp sensor if damaged.
B. If no problems are determined, proceed to step 3.

3. Operation: Check Supply Voltage for Fuel temp sensor.
Remove connector from Fuel temp sensor and check for voltage outlined in the table below.

1. Voltage KTF (Pin 1) KTF (Pin 2) Approx. 5 volts
A. If the voltage test is successful, proceed to step 5.
B. If the voltage test is not successful, proceed to step 4.

Remove and perform continuity tests between connector KTF and connector 2 on engine sensor harness. Flex
harness during test to check for any intermittent operation. See test table below.
Important Note:

1. Continuity KTF (Pin: 1) 2 (Pin: 35) Approx. 0 - 0.10 ohms
2. Continuity KTF (Pin: 2) 2 (Pin: 17) Approx. 0 - 0.10 ohms
3. Short Circuit KTF (Pin: 35) 2 (Pin: 32) Open Circuit
47365539 08/07/2012
55.DTC / 137
4. Short Circuit 2 (Pin: 35) 2 (Pin: 33) Open Circuit
5. Operation: Fuel temp sensor Test
Remove Fuel temp sensor connector KTF and test resistance of Fuel temp sensor using the table of resistance
vs. temp. below. Approximate the fuel temperature when performing test. Fuel temp sensor failures are typically
at the extreme ends of the table or off the table entirely.
Fuel Temperature Resistance Value

-20 °C (-4 °F) 10.5 kOhm
0 °C (32 °F) 7500 ohms
20 °C (68 °F) 4200 ohms
40 °C (104 °F) 980 ohms
60 °C (140 °F) 780 ohms
80 °C (176 °F) 500 ohms
100 °C (212 °F) 280 ohms
120 °C (248 °F) 97 ohms
Use product schematic, remove the connector from the ECU and check for voltage and continuity at the appro-
priate pins defined in the test table below.
Important Note:

1. Voltage Connector 1 (Pin 2, 3, 8, 9, Ground (engine block) Approx. 12 volts
40)
2. Continuity Connector 1 (Pin 5, 6, 10, Ground (engine block) Approx. 0 - 0.10 ohms
11)
A. If the voltages and ground paths are correct and the Fuel temp sensor was not replaced on a prior diag-
nostic of this type, replace the sensor.
B. If the voltages and ground paths are correct and the Fuel temp sensor (FTS) was replaced on a prior
diagnostic of this type, re-initialize the ECU as if it was blank (new) and load the appropriate data-set.
has been resolved.
47365539 08/07/2012
55.DTC / 138
ation.
47365539 08/07/2012
55.DTC / 139
3019-Boost Pressure Sensor - Signal Above Range Maximum

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Pressure sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related to
the pressure sensing function of the device. This error could result from a signal out of range or a signal that is either
erratic or intermittent. When the ECU determines that the Boost Pressure sensor value is not valid, it will substitute a
default value of 270 kPa (39 psi).
Cause:
The Boost Pressure sensor signal to the ECU is out of range of the upper threshold limit.
1. Faulty sensor.
Solution:


2. Operation: Check Open Circuit Voltages for Boost Press sensor.
Remove LDFT connector from Boost Pressure sensor and check for voltages between connector pins outlined
in the table below.


Remove and perform continuity/shorts tests between connectors LDFT and connector 2 on engine wiring har-
ness. Flex harness during test to check for any intermittent operation. See test table below.
Important Note:

2. Continuity LDFT (Pin: 2) LDFT (Pin: 36) Approx. 0 - 0.10 ohms
47365539 08/07/2012
55.DTC / 140

Important Note:

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55.DTC / 141
3022-Boost Pressure Sensor - Signal Not Plausible

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:
The Boost Pressure sensor signal to the ECU and the Atmospheric Pressure Sensor (APS) internal to the ECU do
not agree on engine startup.
1. Faulty sensor.
3. Faulty ECU with integrated APS, supply voltages or grounds.
Solution:


2. Operation: Check Open Circuit Voltages for Boost Press sensor.
Remove LDFT connector from Boost Press sensor and check for voltages between connector pins outlined in
the table below.


ness. Flex harness during test to check for any intermittent operation. . See test table below.
Important Note:

47365539 08/07/2012
55.DTC / 142

Important Note:

A. If the voltages and ground paths are correct and the Boost Press sensor was not replaced on a prior
47365539 08/07/2012
55.DTC / 143
3023-Atmospheric pressure sensor - signal not plausible

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTE: Atmospheric pressure sensor is inside the engine control module, replace ECU. (Not necessary if never run-
ning in high altitude and if turbocharger is without VGT).
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55.DTC / 144
3024-Atmospheric Pressure Sensor - Signal Above Range Maximum

580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 145
3025-Atmospheric pressure sensor - signal below range minimum

580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 146
3028-Oil Pressure Too Low

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) generated a fault associated with the Oil temp / press sensor. The Oil temp / press
sensor is an integrated sensing device used to sense both temperature and pressure. This fault is related to the
pressure sensing function of the device. This fault is a result of a plausibility check of the engine running extremely
low oil pressure. All subsequent engine error states are frozen in case there is a sensor power supply ( 5 volts dc)
error. The ECU only starts the plausibility check if there are no sensor power supply ( 5 volts dc) or Analog to Digital
Converter (ADC) signal or CAN message processing errors detected.
Cause:
The Oil temp / press sensor pressure signal to the ECU is operating at the extreme low end of the signal range.
1. Low engine oil level.

2. Faulty electrical wiring.
3. Faulty engine lubrication system.
4. Faulty Oil temp / press sensor.
Solution:
1. Operation: Inspect Electrical Components and Check Engine Oil Level.

Electrical:
Remove Oil temp / press sensor connector ODFT and inspect housing body/latch, pins and wiring harness for
damage or corrosion. Also, inspect connector portion of the Oil temp / press sensor.
Oil Level:
Check oil level on dipstick.
A. If the engine oil level is low, top off the oil level with the recommended grade of oil specified in the appro-
priate Engine Maintenance and Repair Manual.
B. If electrical damage has been determined after careful inspection, repair wiring and/or replace connector
parts to ensure a good and sound electrical connection. Replace Oil temp / press sensor if damaged.
C. If oil level is proper and no electrical damage has been determined, proceed to step 2.
2. Operation: Check Engine Oil Pressure
Vehicle Status: Key Off Engine Off (test preparation)
Vehicle Status: Key On Engine On (during test)
Use the procedure established in the appropriate Engine Maintenance and Repair Manual to test the pressure
of the engine oil lubrication system.
A. If the oil pressure test is successful, proceed to step 3.
B. If the oil pressure test is not successful, refer to the appropriate Engine Maintenance and Repair Manual
to diagnose, troubleshoot and repair the low oil pressure fault condition.
3. Operation: Check Open Circuit Voltages for Oil temp / press sensor.
Remove ODFT connector from the Oil temp / press sensor and check for voltages (DC) between connector pins
47365539 08/07/2012
55.DTC / 147

1. Voltage ODFT (Pin 3) ODFT (Pin 1) Approx. 5 volts
3. Voltage ODFT (Pin 4) ODFT (Pin 1) Approx. 5.4 volts

Remove and perform continuity tests between connectors ODFT and 2 on engine wiring harness. Flex harness
Important Note: Check and verify that the Vehicle Status is correct. Potential ECU damage could result when
removing main ECU connectors if this is not followed.

1. Continuity ODFT (Pin: 1) 2 (Pin: 24) Approx. 0 - 0.10 ohms
5. Short Circuit 2 (Pin: 28) 2 (Pin: 24, 27, 32) Open Circuit
6. Short Circuit 2 (Pin: 24) 2 (Pin: 27, 32) Open Circuit
Important Note:

A. If the voltages and ground paths are correct and the Oil temp / press sensor was not replaced on a prior
B. If the voltages and ground paths are correct and the Oil temp / press sensor was replaced on a prior
47365539 08/07/2012
55.DTC / 148
3029-Oil Pressure Sensor - Short Circuit To Battery

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
pressure sensing function of the device. This error could result from a signal out of range or a plausibility check (oil
pressure too high). The plausibility check is only started if there are no sensor power supply ( 5 volts dc) or Analog
to Digital Converter (ADC) signal errors detected.
Cause:
The Oil temp / press sensor signal to the ECU is out of range of the upper threshold limit.

2. Faulty electrical wiring, signal short to high source or open circuit condition.
Solution:

good and sound electrical connection. Replace OPS sensor if damaged.

Remove ODFT connector from the Oil temp / press sensor and check for voltages between connector pins



47365539 08/07/2012
55.DTC / 149

Important Note:

47365539 08/07/2012
55.DTC / 150
3030-Oil Pressure Sensor - Short Circuit To Ground

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:
The Oil temp / press sensor signal to the ECU is either erratic or intermittent.
1. Faulty electrical wiring or intermittent connection between Oil temp / press sensor and ECU.
Solution:





47365539 08/07/2012
55.DTC / 151

5. Short Circuit ODFT (Pin: 28) 2 (Pin: 24, 27, 32) Open Circuit
6. Short Circuit ODFT (Pin: 24) 2 (Pin: 27, 32) Open Circuit
7. Short Circuit ODFT (Pin: 27) 2 (Pin: 32) Open Circuit
Use product schematic for a reference, remove 1 connector from the ECU and check for voltage and continuity
Important Note:

47365539 08/07/2012
55.DTC / 152
3031-Oil Pressure Sensor - Hardware Error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:
The Oil temp / press sensor signal to the ECU is either erratic or intermittent.

2. Faulty electrical wiring or intermittent connection between Oil temp / press sensor and ECU.
Solution:





47365539 08/07/2012
55.DTC / 153

Use product schematic for a reference, remove 1 connector from the ECU and check for voltage and continuity
Important Note:

47365539 08/07/2012
55.DTC / 154
3032-Oil Pressure Sensor - Value Too High

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:
The Oil temp / press sensor signals to the ECU are both operating in the extreme upper portion of signal range.

2. Faulty electrical wiring.
4. Faulty engine lubrication system.
5. Low engine oil level.
Solution:
1. Operation: Inspect Electrical Components and Check Engine Oil Level.

Electrical:
Oil Level:
Check oil level on dipstick.
A. If the engine oil level is low, top off the oil level with the recommended grade of oil specified in the appro-
priate Engine Maintenance and Repair Manual.
B. If electrical damage has been determined after careful inspection, repair wiring and/or replace connector
parts to ensure a good and sound electrical connection. Replace Oil temp / press sensor if damaged.
C. If oil level is proper and no electrical damage has been determined, proceed to step 2.
47365539 08/07/2012
55.DTC / 155



Important Note:

47365539 08/07/2012
55.DTC / 156
3033-Oil Temperature Sensor - Signal Not Plausible (Compared

With Coolant Temperature)
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
temperature sensing function of the device. This error could result from a signal out of range or a plausibility check
against the Coolant temp sensor or CAN message processing. The ECU prohibits any plausibility check if there are
any Analog to Digital Converter (ADC) signal errors detected on the Oil temp / press or the Coolant temp sensor.
Cause:
The Oil temp / press and Coolant temp sensor signals to the ECU are out of range with respect to each other.
1. Faulty Oil temp / press sensor (inaccurate).

2. Faulty Coolant temp sensor (inaccurate).
3. Faulty electrical wiring, high resistance connections.
5. Faulty oil lubrication or coolant system.
Solution:
1. Operation: Check for Coolant System Faults.
Use EST to check for errors associated with coolant temperature.
A. If any of the errors exist, resolve the existing error. Then determine if this error has also been resolved.
B. If none of the errors exist, continue with step 2.

good and sound electrical connection. Replace Oil temp / press sensor if damaged.



4. Operation: Oil temp / press sensor Test
47365539 08/07/2012
55.DTC / 157
Remove ODT connector and test resistance of Oil temp / press sensor using the table of resistance vs. temp.
below. Approximate the engine oil temperature when performing test. Use a multi-meter between pins 1 and 2.
Engine Oil Temperature Resistance Value (between pins 1 and 2)

-40 °C (-40 °F) 70 kOhm
-20 °C (-4 °F) 25 kOhm
0 °C (32 °F) 7.5 kOhm
20 °C (68 °F) 4.5 kOhm
40 °C (104 °F) 1.5 kOhm
60 °C (140 °F) 750 ohms
80 °C (176 °F) 550 ohms
100 °C (212 °F) 320 ohms
120 °C (248 °F) 130 ohms

Important Note:

47365539 08/07/2012
55.DTC / 158
47365539 08/07/2012
55.DTC / 159
3034-Oil Temperature Sensor - Signal Above Range Maximum

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:
The Oil temp / press sensor signal to the ECU is out of range of the upper threshold limit.

2. Faulty electrical wiring, signal short to high source or open circuit condition.
Solution:




Remove and perform continuity tests between connectors ODT and 2 on engine wiring harness. Flex harness

4. Continuity ODFT (Pin: 4) (Pin: 27) Approx. 0 - 0.10 ohms
47365539 08/07/2012
55.DTC / 160
5. Short Circuit 2 (Pin: 28) 2 2 (Pin: 24, 27, 32) Open Circuit
Important Note:

47365539 08/07/2012
55.DTC / 161
3035-Oil Temperature Sensor - Signal Below Range Minimum

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:
The Oil temp / press sensor signal to the ECU is out of range of the lower threshold limit.

2. Faulty electrical wiring, signal short to low source condition.
Solution:





47365539 08/07/2012
55.DTC / 162
Important Note:

47365539 08/07/2012
55.DTC / 163
3037-Boost Pressure Sensor - Signal Low

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:
The Boost Pressure sensor signal to the ECU is out of range of the lower threshold limit.
1. Faulty sensor.
Solution:


Remove connector from Boost Pressure sensor and check for voltages (DC) between connector pins outlined
in the table below.


ness. Flex harness during test to check for any intermittent operation. See test table below.
Important Note:

47365539 08/07/2012
55.DTC / 164

Important Note:

47365539 08/07/2012
55.DTC / 165
3051-Battery Voltage To Engine Controller - Voltage Too High

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTICE: Check alternator output voltage, if above 18 V troubleshoot the charging system before proceeding.
Context:
The battery supply to the ECM is above the threshold. Verify the alternator output before continuing.
Cause:
1. Faulty alternator
2. Faulty ECM
Solution:
rence.
(1) Turn ignition switch to ON position.
(2) Clear all fault codes.
A. NOT OK – Fault code 3051 is recorded again. Go to Step 2.
B. OK – Fault is not recorded again. OK for return to service.

2. Measure the ECU unswitched input voltage
(1) Turn ignition OFF. Disconnect Engine Control Unit (ECU) connector X-461 from engine controller.
RCPH11TLB096AAL 1 RCPH11TLB054BAD 2
(2) Inspect pins on Engine Control Unit (ECU) connector and on engine controller. Clean connections.
(3) Turn the ignition ON.
(4) Measure the voltage from pins 1, 3, 5, and 28 on ECU connector X-461 to ground (ECU connector X-461
pins 2, 4, and 6). The voltage should be approximately 14.5 V.
A. The voltage is correct. Temporarily replace the ECU and retest. Go to Step 1 to confirm elimination of the
fault.
B. The voltage is greater than 15 volts. Temporarily replace the alternator and retest. Go to Step 1 to confirm
47365539 08/07/2012
55.DTC / 166
3052-Battery Voltage To Engine Controller - Voltage Too Low

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTICE: Check the battery output voltage, if below 10 V charge the battery before proceeding.
1. Low battery voltage.

3. Wiring or circuits shorted.
4. Faulty ECU
Solution:
1. Verify that fault code 3052 is still active, refer to 0000 - Retrieving fault codes, Backhoes.
rence.

A. The voltage is approximately 14.5 V. Temporarily replace the ECU and retest. Go to Step 1 to confirm
elimination of the fault.
B. The voltage is less than 10 V. Temporarily replace the alternator and retest. Go to Step 1 to confirm
47365539 08/07/2012
55.DTC / 167
3059-ECM afterrun was interrupted

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTICE: Fault Code 3059 is stored in historical information. For multiple occurrences of this fault proceed with the
following tests.
Cause:

Solution:
rence.

A. NOT OK – Check fuses and wiring to ECU. Return to Step 1 to confirm elimination of fault.
3. Test alternator, refer to Alternator - Malfunction (55.301).
47365539 08/07/2012
55.DTC / 168
A. NOT OK – Replace alternator. Return to Step 1 to confirm elimination of fault.
4. Replace the engine control module.
(1) Remove and replace engine control module.
for assistance.
47365539 08/07/2012
55.DTC / 169
3060-Cylinder 1 - Unclassifiable Error In Injector

Context:
The engine control unit (ECU) has determined that an unclassifiable failure exists in the Cylinder #1 injector circuit.
A power stage component energizes the injection system transistors and simultaneously observes the current flow
in the high-side and low-side switching branch by sensing resistors. If there is a deviation from the expected current
flow the component detects specific errors and reports them to the ECU. This error message is then rearranged so
it holds information on performed injections, errors of cylinders on the same bank, bank specific errors and cylinder
specific errors. The rearranged error message is then compared to applicable error patterns and if there is a match
the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect
is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of
a failure in the Cylinder #1 injector circuit that is unclassifiable over 8 camshaft revolutions. As a result of this error an
individual cylinder or bank is shut off, based on parameters established in the ECU. Certain parameters, as currently
applied, are permanent (without a healing possibility, once tested by switching on the component to see if the defect
is still present). and others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the injector output power driver
stage.
1. Faulty injection valve.

2. Faulty electrical wiring (damaged connector or conductor).
3. Faulty ECU, hardware or software.
Solution:

2. Visually check the electrical integrity of the injector circuit (Inspect connector housing body/latch, pins and wiring
harness for damage or corrosion).
B. If no damage is determined, the ECU or injector may have failed. Try reloading the ECU software. If the
fault reoccurs, try replacing the injector. If the fault reoccurs, replace the ECU.
has been resolved.
ation.
47365539 08/07/2012
55.DTC / 170
3061-Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery)

NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to be able to take accurate re-
sistance measurements.
Context:
The Engine Control Unit (ECU) generated an error associated with the injector power driver stage. The power stage
component of the ECU energizes the injection system transistors and simultaneously observes the current flow (sense
resistors) in the high-side and low-side switching branches. If there is a deviation from the expected current flow, the
driver circuitry detects the specific error and reports it back to the ECU. The ECU will process the error message so
that it records information on performed injections, cylinder bank specific errors and cylinder specific errors. The error
message is then compared to applicable error patterns and if there is a match, a fault code is generated. If an error
message doesn't match any pattern, the error is treated as unclassifiable. This monitoring function is performed once
per camshaft revolution.
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of the
injector output power driver stage.
1. Faulty injection valve or shorted solenoid windings.

2. Faulty electrical wiring, short to high source or damaged wiring harness.
Solution:

Remove the following connector for electrical inspection:

1. ECU injector connector 3.
2. Valve cover connector VC1.
Inspect connector housing body/latch, pins and wiring harness for damage or corrosion.

2. Operation: Injector Resistance Test Cylinder #1/2 injector connector VC1 to Cylinder #1/2 injector.
Remove connector VC1 and perform an injector resistance test on the Cylinder #1/2 injector connector VC1.
Use the standard multi-meter test leads to access the connector pins. See test table below.

1. Resistance Cylinder #1/2 injector con- Cylinder #1/2 injector con- Approx. 0.4 - 0.5 ohms
nector VC1. connector nectorVC1 connector pin:
pin: 3 4
A. If resistance test was not successful, proceed to step 4
B. If resistance test was successful, reconnect connector VC1. Proceed to step 3.

3. Operation: Injector Resistance Test ECU harness side of connector 3 to Cylinder #1 injector.
Remove ECU connector and perform an injector resistance test. See test table below.
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1. Resistance ECU harness connector 3, ECU harness connector 3, Approx. 0.4 - 0.5 ohms
pin: 4 pin: 13
A. If resistance test was not successful, repair wiring harness between ECU harness connector and connec-
tor VC1.
B. If resistance test was successful, proceed to step 5.

4. Operation: Standalone Injector Resistance Test.
Remove valve cover from the top of the head to allow access to the internal injector wiring harness. Remove the
Cylinder #1 injector connector (two flying leads with ring terminals). Perform a resistance test on the terminals
located on top of the solenoid portion of the injector. Make sure that the multi-meter's test lead resistance is taken
into consideration when resistance measurements are taken. Record the multi-meter's test lead resistance by
touching the leads together on the lowest Ohms scale and mentally recording the resistance value. Subtract
this value from the actual resistance measurement taken. See test table below.

1. Resistance Cylinder #1 injector, con- Cylinder #1 injector, con- Approx. 0.4 - 0.5 ohms
nector INJ1, terminal #1 nector INJ1, terminal #2
A. If resistance test was successful, repair the internal harness between the Cylinder #1 injector and the
connector INJ1.
B. If resistance test was not successful, replace the Cylinder #1 injector.

Vehicle Status (when removing ECU connector 1) Key Off Engine Off.
Vehicle Status (when performing test) Key On Engine Off.
Vehicle Status (when replacing ECU connector 1) Key Off Engine Off.
Remove connector 1 from the ECU and check for voltage and continuity at the appropriate pins defined in the
test table below.
Important Note: Check and verify that the Vehicle Status is correct for each operation. Potential ECU damage
could result when removing and replacing main ECU connectors if this is not followed.

1. Voltage ECU connector 1, pin 2, 3, Ground (engine block) Approx. 12.0 volts (DC)
8, 9, 40
2. Continuity ECU connector 1, pin 5, 6, Ground (engine block) Approx. 0.0 - 0.1 ohms
10, 11
A. If the voltages and ground paths are correct, proceed to step 6.
B. If the voltages and ground paths are not correct, refer to product schematic and determine root cause of
power and/or continuity problem(s).
6. Operation: Re-initialize the ECU.
Using the EST service tool, re-initialize the ECU and load the appropriate data-set for this engine type. A call
will have to be made to CNH TSS to get an authorization code for the ECU initialization download. Check to
see if the fault code has cleared.
A. If the fault code did not clear, Replace the ECU.
B. If fault code cleared, continue with operation of machine.

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3062-Cylinder 1 - Electronic injector , Low signal

Cause:

Solution:
rence.
(1) Turn ignition switch to RUN position to power instrument cluster.
(2) Clear all fault codes from the cluster.

2. Check circuits from engine controller to injector connector.
(1) Disconnect Engine Control Module (ECU) connector X-462 and inspect pins, wiring and connectors for dam-
age, abrasion, corrosion or incorrect attachment.
(2) Disconnect injector connectors for cylinders 1 and 2. Inspect pins, wiring and connectors for damage, abra-
sion, corrosion or incorrect attachment.
(3) Measure the resistance from ECU connector X-462, pin 16, to injector connector pin 1. The resistance
should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. NOT OK— Determine the break between connectors and repair. Return to Step 1 to confirm elimination
of fault.
B. OK— Go to Step 3.
3. Check circuits from rocker housing connector to injector 1.
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(1) Remove engine valve cover.
NOTE: During installation of valve cover, tighten mounting nuts to a torque of 20 - 30 Nm (15 - 22 lb ft).
(2) Disconnect leads from number 1 injector.
NOTE: When installing leads on injectors, torque terminal nuts to general bolt torque specifications.
(3) Check for open circuit from injector 1 leads to pins 1 and 2 of connector in rocker housing, a reading of
continuity should be obtained.
(4) Check for short circuit between pins 1 and 2 of connector in rocker housing, an open circuit should be ob-
tained.
(5) Check for short circuit between pins 1 and 2 of connector in rocker housing and ground, an open circuit
should be obtained.
A. NOT OK— Determine the break or short between connectors and repair. Return to Step 1 to confirm
4. Check injector.
(2) Take an Ohm reading between terminals on number 1 injector, a reading of 0.5 - 1.0 Ω at 20 °C (68.0 °F)
should be obtained.
A. NOT OK— Replace injector as needed. Return to Step 1 to confirm elimination of fault.
Prior to changing the engine control module contact Technical Services Group for further assistance.
(2) Write symptom on failed engine control module.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again contact Technical Services Group
for assistance.
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3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground)

NOTE: This diagnostic procedure requires a good quality multi-meter to be able to take accurate resistance measure-
ments. The meter should be able to measure to a resolution of 0.1 ohms. Some of the measurements required to
be taken, could be as low as 0.4 ohms (typical injector solenoid coil resistance is 0.4 - 0.5 Ω) and any inaccuracies
in the DMM could cause a technician to take the wrong diagnostic path.
Context:
The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 1. A
power stage component energizes the unit injection system transistors and simultaneously observes the current flow
flow the component detects specific errors and reports them to the ECU . This error message is then rearranged so
is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result
of a short circuit of the high side to the low side or ground over 3 camshaft revolutions. As a result of this error an
individual cylinder or bank is shut off, based on parameters established in the ECU . Certain parameters, as currently
Cause:
1. Faulty cylinder 1 solenoid windings.

2. Faulty electrical wiring, short high side to low side or ground (damaged wiring harness).
3. Faulty ECU, ECU hardware or software.
Solution:

2. Carefully disconnect the engine cylinder harness from the ECU at ECU cylinder harness connector 3. Use a
multi-meter to check the resistance, on the cylinder harness side of connector 3, between pins 4 and 13. There
should be 0.4 - 0.5 Ω.
A. If the resistance was within range, leave ECU cylinder connector 3 disconnected and continue with step 3
B. If the resistance was lower than range minimum, continue with step 6.
3. Use a multi-meter to check for continuity, on the ECU cylinder harness side of connector 3, from pin 4 to chassis
ground and pin 13 to chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, continue with step 4
B. If there was no continuity on either pin to chassis ground, the ECU may have failed. Try reloading the ECU
software and if the fault reoccurs, replace the ECU .
4. Disconnect the engine cylinder harness from the injector (valve) cover at connector VC1. Use a multi-meter to
check for continuity, on the injector (valve) cover side of connector VC1 from pin A to chassis ground and pin B
to chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, leave connector VC1 disconnected and
continue with step 5
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B. If there was no continuity on either pin to chassis ground, there is a short to ground condition in the engine
cylinder harness between Valve cover connector VC1 and ECU to cylinder harness connector 3. Locate
and repair the grounded conductor.
5. Remove the injector (valve) cover and disconnect the injector harness from Cylinder 1 injector at connector INJ1
terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the injector, from terminal 1 to
chassis ground. There should not be continuity.
A. If there is continuity, Cylinder 1 injector's solenoid coil has failed, replace the injector.
B. If there is no continuity, there is a short to ground condition in Cylinder 1 injector circuit, between connector
INJ1 and connector VC1. Locate and repair the grounded conductor.
6. Disconnect the engine injector harness from the injector cover at Cylinder 1 /2 valve cover connector VC1 and
use a multi-meter to check the resistance on the injector cover side of Cylinder 1 /2 valve cover connector VC1
between pins A and B. There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, there is a short circuit condition in the engine injector harness between
the Cylinder 1 / 2 valve cover connector VC1 and ECU cylinder harness connector 3, locate and repair the
short circuit.
B. If the resistance was lower than range minimum, continue with step7
7. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder 1 injector at connector
INJ1 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder 1 injector, from
terminal 1 to terminal 2. There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, there is a short circuit condition in the injector harness, between Cylinder
1 injector connector INJ1 and connector VC1. Locate and repair the shorted conductors.
B. If the resistance was lower than minimum range, the Cylinder 1 injector solenoid coil has failed. Replace
the injector.
has been resolved.
ation.
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Context:
Cause:
stage.

Solution:

has been resolved.
ation.
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Context:
Cause:

Solution:




nector VC2 connector pin: nector VC2 connector pin:
3 4

Remove ECU connector 3 and perform an injector resistance test. See test table below.
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1. Resistance ECU harness connector, ECU harness connector 3, Approx. 0.4 - 0.5 ohms
pin: 12 pin: 5
tor VC2.


nector INJ3 terminal #1 nector INJ3 terminal #2
connector INJ3.

test table below.

8, 9, 40
10, 11

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3070-Cylinder 3 - Electronic injector , Low signal

Cause:
1. Engine misfires, runs erratic.

Solution:
rence.

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BD08J014-01 3
(1) Connector injectors (for cylinders 3 and 4)

(2) High pressure common rail
(3) Check for open circuit from ECU connector X-462, pin 31to injector connector pin 1. The resistance should
be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(4) Check for open circuit from ECU connector X-462, pin 1 to injector connector pin 2. The resistance should
(5) Measure the resistance between pins 1 and 31 on ECU connector X-462. The resistance should be greater
than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(3) Check for open circuit from injector 3 leads to pins 1 and 2 of connector in rocker housing, a reading of
continuity should be obtained.
(4) Check for short circuit between pins 1 and 2 of connector in rocker housing, an open circuit should be ob-
tained.
(5) Check for short circuit between pins 1 and 2 of connector in rocker housing and ground, an open circuit
should be obtained.
4. Check injector.
(2) Take an Ohm reading between terminals on number 3 injector, a reading of 0.5 - 1.0 Ω at 20 °C (68.0 °F)
should be obtained.
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for assistance.
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NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to be able to take accurate resis-
tance measurements. The meter should be able to measure to a resolution of 0.1 ohms. Some of the measurements
required to be taken, could be as low as 0.4 ohms (typical injector solenoid coil resistance is 0.4 - 0.5 Ω) and any
inaccuracies in the DMM could cause a technician to take the wrong diagnostic path.
Context:
The engine control unit (ECU) has determined that a short circuit exists in the high side injector circuit for cylinder 3.
the failure corresponding to the matched pattern is output. If an error message does not match any pattern the defect
is still present) and others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:

Solution:
1. Carefully disconnect the engine injector harness from the ECU at connector 3. Use a multi-meter to check the
resistance, on the ECU engine injector harness side of connector 3, between pins 12 and 5. There should be
0.4 - 0.5 Ω.
A. If the resistance was within range, leave ECU harness connector 3 disconnected, and continue with step
2.
2. Use a multi-meter to check for continuity, on the ECU engine injector harness side of connector 3, from pin 12
to chassis ground and pin 5 to chassis ground. There should not be continuity.
A. If there was continuity on either or both pins to chassis ground, continue with step 3.
software and if the fault reoccurs, replace the ECU.
3. Disconnect the engine injector harness from the injector (valve) cover at connector VC2. Use a multi-meter to
check for continuity, on the injector (valve) cover side of connector VC2 from pin 3 to chassis ground and pin 4
continue with step 4.
injector harness between connector VC2 and ECU harness connector 3. Locate and repair the grounded
conductor.
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4. Remove the injector (valve) cover and disconnect the injector harness from Cylinder #3 injector at connector
INJ3 terminal 1 (high side ring terminal) Use a multi-meter to check for continuity, on the Cylinder #3 injector,
from terminal 1 to chassis ground. There should not be continuity.
A. If there is continuity, the Cylinder #3 injector solenoid coil has failed, replace the injector.
B. If there is no continuity, there is a short to ground condition in the Cylinder #3 injector circuit, between
connector INJ3 and connector VC2. Locate and repair the grounded conductor.
5. Disconnect the engine injector harness from the injector cover at connector VC2 and use a multi-meter to check
the resistance on the injector cover side of connector VC2 between pins 3 and 4. There should be 0.4 - 0.5 Ω.
connector VC2 and ECU harness connector 3, locate and repair the short circuit.
6. Remove the injector (valve) cover and disconnect the injector harness from the Cylinder #3 injector at connector
from terminal 1 to terminal 2. There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, there is a short circuit condition in the injector harness, between con-
nector INJ3 and connector VC2. Locate and repair the shorted conductors.
B. If the resistance was lower than minimum range, the Cylinder #3 injector solenoid coil has failed. Replace
the injector.
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Context:
Cause:
stage.

Solution:

has been resolved.
ation.
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Context:
Cause:

Solution:




1 2

Remove ECU connector and perform an injector resistance test. See test table below.
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1. Resistance ECU harness connector, ECU harness connector, Approx. 0.4 - 0.5 ohms
pin: 11 pin: 6
tor VC1.

located on top of the solenoid portion of the injector. See test table below.

connector INJ2 .

test table below.

8, 9, 40
10, 11

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3078-Cylinder 2 - Electronic injector, Low signal

Cause:

Solution:
rence.

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BD08J015-01 3
(1) Rail pressure sensor

(3) Measure the resistance from ECU connector X-462, pin 2 to injector connector pin 2. The resistance should
(4) Measure the resistance from ECU connector X-462, pin 46 to injector connector pin 4. The resistance should
(5) Measure the resistance between ECU connector X-462 pins 46 and 2. The resistance should be greater
(3) Measure the resistance from injector 2 leads to pins 3 and 4 of connector in rocker housing. The resistance
(4) Measure the resistance between pins 3 and 4 of connector in rocker housing. The resistance should be
(5) Measure the resistance between pins 3 and 4 of connector in rocker housing and ground (engine block).
4. Check injector.
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(2) Measure the resistance between terminals on number 2 injector. The resistance should be between 0.5 -
1.0 Ω at 20 °C (68.0 °F).
for assistance.
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Context:
Cause:

Solution:
0.4 - 0.5 Ω.
2.
2. Use a multi-meter to check for continuity, on the ECU engine injector harness side of connector 3, from pin 11
to chassis ground and pin 6 to chassis ground. There should not be continuity.
injector harness between connector VC1 and ECU harness connector 3. Locate and repair the grounded
conductor.
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connector VC1 and connector VC1. Locate and repair the grounded conductor.
the injector.
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Context:
Cause:
stage.

Solution:

has been resolved.
ation.
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Context:
Cause:

Solution:




1 2

Remove ECU connector 3 and perform an injector resistance test. See test table below.
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1. Resistance ECU harness connector 3, ECU harness connector 3, Approx. 0.4 - 0.5 ohms
pin: 3 pin: 14
A. If resistance test was not successful, repair wiring harness between ECU harness connector 3 and con-
nector VC2.


connector INJ4.

test table below.

8, 9, 40
10, 11

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3082-Cylinder 4 - Electronic injector, Low signal

Cause:

Solution:
rence.

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BD08J014-01 3

(3) Measure the resistance from ECU connector X-462 , pin 17, to injector connector pin 3. The resistance
(5) Measure the resistance between pins 17 and 48 on ECU connector X-462. The resistance should be greater
(3) Measure the resistance from injector 4 leads to pins 3 and 4 of connector in rocker housing. The resistance
(4) Measure the resistance between pins 3 and 4 of connector in rocker housing. The resistance should be
(5) Measure the resistance between pins 3 and 4 of connector in rocker housing and ground (engine block).
4. Check injector.
(2) Measure the resistance between terminals on number 4 injector, a reading of 0.5 - 1.0 Ω at 20 °C (68.0 °F) .
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for assistance.
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Context:
Cause:

Solution:
0.4 - 0.5 Ω.
2.
2. Use a multi-meter to check for continuity, on the ECU engine injector harness side of connector 3, from pin 3 to
chassis ground and pin 14 to chassis ground. There should not be continuity.
injector harness between connector VC2 and ECU harness connector 3.Locate and repair the grounded
conductor.
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connector INJ4 and connector VC2. Locate and repair the grounded conductor.
the injector.
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3088-Crankshaft sensor lost synchronization

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Increment speed (Crankshaft speed)
sensor. If the engine has a defective Crankshaft speed sensor it can run off the Segment speed (Camshaft speed)
sensor. This is referred to as BACKUP mode. Diagnostics of the SIG failure is only active if voltage is present at
terminal 15 (Ignition ON) and no errors are active for the sensor supply voltage.
Cause:
The ECU has determined that there is no signal from the Crankshaft speed sensor. The engine is now operating in
BACKUP mode.
1. Faulty Crankshaft speed sensor.

2. Faulty electrical wiring and/or connections.
3. Faulty ECU, or ECU supply voltages or grounds.
Solution:

2. Remove Crankshaft speed sensor connector DG6 Incr and inspect housing body/latch, pins and wiring harness
for damage or corrosion. Also, inspect connector portion of the Crankshaft speed sensor.
good and sound electrical connection. Replace Crankshaft speed sensor if damaged.
B. If no damage is determined, leave connector disconnected and proceed to step 3.

3. Operation: Resistance Check for Faulty CKP, Engine flywheel RPM, sensor.
Vehicle Status: Key Off Engine Off
Measure the resistance between the crankshaft speed sensor pins 1 and 2.
Test Type From To Results (Min) Results (Max)

1. Resistance Crankshaft speed Crankshaft speed 750 ohms 1000 ohms
sensor connector sensor connector
DG6 Incr, (Pin 1) DG6 Incr, (Pin 2)
A. If the resistance test does not fall in the specified range, replace Crankshaft speed sensor.
B. If the resistance test does fall in the specified range, leave connector disconnected and proceed to step 4.
4. Operation: Check Output of Crankshaft speed sensor.
Vehicle Status: Key Off Engine Off (test setup)
Single Ended Test Lead Connection Test (Standalone Crankshaft speed sensor Test)
Remove Crankshaft speed sensor connector and connect the above mentioned special test lead to the Crank-
shaft speed sensor. Start the engine and measure the (AC) voltage using a multi-meter across the breakout
alligator clips from the test leads. Use the test table below to determine the measurement results.
In-Line Test Lead Connection Test:

Remove Crankshaft speed sensor connector and connect the above mentioned special test lead in-line with the
sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection
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process. Start the engine and measure the (AC) voltage using a multi-meter across the breakout alligator clips
from the test leads. Use the test table below to determine the measurement results.
Note:
The engine will be running off the Camshaft speed sensor during the single ended test, if it isn't already (based
on the fault code type). The engine can also be very hard to start when running exclusively off the Camshaft
speed sensor. The ECU needs to see a few revolutions of the camshaft to be able to use this information to
start the engine.
The Crankshaft speed sensor and the Camshaft speed sensor are exactly the same. These sensors may be
swapped in this diagnostic procedure to determine the functionality of the Crankshaft speed sensor. A new set
of error codes may be generated by the ECU if the sensors are swapped.

1. Voltage (AC) - Single Crankshaft speed sensor Crankshaft speed sensor Approx. 16 - 18 volts (AC)
ended connection at low connector DG6 Incr, (Pin connector DG6 Incr, (Pin
RPM ( 1000 - 1100 RPM) 1) 2)
ended connection at high connector DG6 Incr, (Pin connector DG6 Incr, (Pin
RPM ( 2000 - 2200 RPM) 1) 2)
3. Voltage (AC) - In-line Crankshaft speed sensor Crankshaft speed sensor Approx. 10 - 12 volts (AC)
connection at low RPM ( connector DG6 Incr, (Pin connector DG6 Incr, (Pin
1000 - 1100 RPM) 1) 2)
connection at high RPM ( connector DG6 Incr, (Pin connector DG6 Incr, (Pin
2000 - 2200 RPM) 1) 2)
A. If the voltage test was successful, proceed to step 6.
B. If the voltage test was not successful for any of the single ended connections, replace the sensor.
C. If the voltages encountered during testing are low and the sensor was replaced on a prior diagnostic pro-
cedure of this type, ensure the Crankshaft speed sensor is installed properly.
D. If the voltage test was successful for the single ended connections and not for any of the in-line connec-
tions, leave the connector disconnected and proceed to step 5.
Perform continuity tests between connector DG6 Incr and connector 2 on ECU engine harness. Flex harness

1. Continuity Crankshaft speed sensor ECU engine harness con- Approx. 0 - 0.10 ohms
connector DG6 Incr, (Pin: nector 2, (Pin: 23)
1)
2)
3. Short Circuit ECU engine harness con- ECU engine harness con- Open Circuit
nector 2, (Pin: 23) nector 2, (Pin: 19)
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Using the product schematics for a reference, remove connector 1 from the ECU and check for voltage and
continuity at the appropriate pins defined in the test table below.

1. Voltage ECU vehicle harness con- Ground (engine block) Approx. 12 volts (DC)
nector 1, (Pin: 2, 3, 8, 9,
40)
2. Continuity ECU vehicle harness con- Ground (engine block) Approx. 0 - 0.10 ohms
nector 1, (Pin: 5, 6, 10, 11)
A. If the voltages and ground paths are correct and the Crankshaft speed sensor was not replaced on a prior
diagnostic procedure of this type, replace the sensor.
B. If the voltages and ground paths are correct and the Crankshaft speed sensor was replaced on a prior
diagnostic procedure of this type and the sensor mechanical alignment and spacing was verified, re-ini-
tialize the ECU as if it was blank (new) and load the appropriate data-set.
type, replace the ECU .
D. If the voltages and ground paths are not correct, refer to product schematics and determine root cause of
has been resolved.
ation.
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3089-Crankshaft Sensor - Invalid Signal

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Crankshaft speed sensor. If the engine
has a defective Crankshaft speed sensor it can run off the Camshaft speed sensor. This is referred to as BACKUP
mode. Diagnostics of the FMI=3 failures is only active if terminal 40 is on (KEY ON) and no errors are reported in the
sensor supply voltage. For the FMI=4 failures, additional conditions for active diagnostics are included, such as the
engine must be in startup mode and the engine speed must be above 450 RPM.
Cause:
The ECU has determined that there are errors in the signal from the Crankshaft speed sensor.

3. Faulty ECU, supply voltages or ground paths.
Solution:

2. Inspect the Crankshaft speed sensor. Remove the Crankshaft speed sensor connector DG6 Incr, and inspect
housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect the connector portion of the
Crankshaft speed sensor.

3. Measure the internal resistance of Crankshaft speed sensor. Remove Crankshaft speed sensor connector. Use
a multi-meter to measure the resistance between pins 1 (yellow) and 2 (red) of the Crankshaft speed sensor.
There should be between 825 - 975 Ω at 20 °C (68 °F).
A. If the resistance is not within the specified range, replace the Crankshaft speed sensor.
B. If the resistance is within the specified range, proceed to step 4.

4. Measure the AC voltage from Crankshaft speed sensor output. Use a multi-meter to check for voltage while
starting the engine. Measure the voltage between pins 1 (yellow) and 2 (red) of the Crankshaft speed sensor
connector, DG6 Incr. here should be a minimum of .50 V while cranking and a higher reading once the engine
starts.
A. If the voltage is less than .50 V (AC), replace the sensor.
B. If the voltage is above .50 V (AC), proceed to step 5.

5. Check for faulty wiring between the Crankshaft speed sensor and the ECU. Measure resistance between the
Crankshaft speed sensor, DG6 Incr, pin 2, and the ECU engine connector 2, pin 23.
A. If there is continuity, go to step 6.
B. If there is no continuity, find and repair the damaged wiring between connector DG6 Incr, pin 2 and 2 , pin
23.
6. Check voltage and ground supply to ECU. Disconnect ECU vehicle connector 1 and use a multi-meter to verify
the ECU has sufficient supply voltage and ground paths. Use the table below as a reference.
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1. Voltage ECU vehicle connector 1, Ground (engine block) Approx. 12 volts (DC)
(Pin: 2, 3, 8, 9, 40)
2. Continuity ECU vehicle connector 1, Ground (engine block) Approx. 0 - 0.10 ohms
(Pin: 5, 6, 10, 11)
A. If the voltage supply and ground paths are sufficient, continue with step 7.
B. If the voltage supply and ground paths are not present, use the vehicle schematics to find and repair the
cause.
7. Visually inspect the relevant harnesses and connectors for damage, bent, or dislocated pins, corroded terminals
breaks or shorts in the wiring concerned. Operate the machine while monitoring the display.
has been resolved.
ation.
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3090-Phase defect of camshaft speed sensor signal detected

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Segment speed sensor (Camshaft
speed sensor). If the engine has a defective Camshaft speed sensor it can run off the Increment speed sensor (Crank-
shaft speed sensor). Diagnostics is active if voltage is present at terminal 15 (Ignition On),, the current engine speed
is above 50 RPM, no error in the Crankshaft speed sensor is present and the sensor supply voltage ( 5 volts DC) is
not defective.
Cause:
The ECU has determined that there is no signal from the Camshaft speed sensor.
1. Faulty Camshaft speed sensor.

2. Camshaft speed sensor is not mechanically installed correctly.
Solution:

2. Remove Camshaft speed sensor connector DG6 Segm and inspect housing body/latch, pins and wiring harness
for damage or corrosion. Also, inspect connector portion of the Camshaft speed sensor.
good and sound electrical connection. Replace Camshaft speed sensor if damaged.

3. Operation: Resistance Check for Faulty Camshaft speed sensor.
Measure the resistance between Camshaft sensor pins 1 and 2. See test table below.

1. Resistance Camshaft speed Camshaft speed 750 ohms 1000 ohms
DG6 Segm (Pin 1) DG6 Segm (Pin 2)
A. If the resistance test does not fall in the specified range, replace Camshaft speed sensor.
4. Operation: Check Output of Camshaft speed sensor.
Make the following electrical tests in the table below.

Single Ended Test Lead Connection Test (Standalone Camshaft speed sensor Test).
Remove Camshaft speed sensor connector DG6 Segm and connect the above mentioned special test lead to
the Camshaft speed sensor. Start the engine and measure the (AC) voltage using a multi-meter across the
breakout alligator clips from the test leads. Use the test table below to determine the measurement results.
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Remove Camshaft speed sensor connector DG6 Segm and connect the special test lead in-line with the sensor
and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process.
Start the engine and measure the (AC) voltage using a multi-meter across the breakout alligator clips from the
test leads. Use the test table below to determine the measurement results.
Note:
The engine will be running off the Crankshaft speed sensor during this test. The Camshaft speed sensor and the
Crankshaft speed sensor are exactly the same. These sensors may be swapped in this diagnostic procedure
to determine the functionality of the Camshaft speed sensor. A new set of error codes may be generated by the
ECU if sensors are swapped.

1. Voltage (AC) - Single Camshaft speed, sensor Camshaft speed, sensor Approx. 2 - 3 volts (AC)
ended connection at low connector DG6 Segm (Pin connector DG6 Segm (Pin
RPM ( 1000 - 1100 RPM) 1) 2)
ended connection at high connector DG6 Segm (Pin connector DG6 Segm (Pin
RPM ( 2000 - 2200 RPM) 1) 2)
3. Voltage (AC) - In-line Camshaft speed, sensor Camshaft speed, sensor Approx. 1.5 - 2.8 volts
connection at low RPM ( connector DG6 Segm (Pin connector DG6 Segm (Pin (AC)
1000 - 1100 RPM) 1) 2)
4. Voltage (AC) - In-line Camshaft speed, sensor Camshaft speed, sensor Approx. 3 - 4.5 volts (AC)
connection at high RPM ( connector DG6 Segm (Pin connector DG6 Segm (Pin
2000 - 2200 RPM) 1) 2)
C. If the voltages encountered during testing are low and the sensor was replaced on a prior diagnostic of
this type, ensure the Camshaft speed sensor was properly installed.
tions, proceed to step 5.
Perform continuity tests between connector DG6 Segm and connector 2 on engine wiring harness. Flex harness

1. Continuity Camshaft speed sensor ECU engine harness con- Approx. 0 - 0.10 ohms
connector DG6 Segm (Pin: nector 2 (Pin: 10)
1)
2)
nector 2 (Pin: 10) nector 2 (Pin: 9)
Vehicle Status (when removing connector 1). Key Off Engine Off.
Vehicle Status (when performing test). Key On Engine Off.
Vehicle Status (when replacing connector 1). Key Off Engine Off.
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1. Voltage ECU vehicle harness 1, Ground (engine block) Approx. 12 volts (DC)
(Pin: 2, 3, 8, 9, 40)
2. Continuity ECU vehicle harness 1, Ground (engine block) Approx. 0 - 0.10 ohms
(Pin: 5, 6, 10, 11)
A. If the voltages and ground paths are correct and the Camshaft speed sensor was not replaced on a prior
B. If the voltages and ground paths are correct and the Camshaft speed sensor was replaced on a prior diag-
nostic procedure of this type and the sensor mechanical alignment and spacing was verified, re-initialize
the ECU as if it was blank (new) and load the appropriate data-set.
has been resolved.
ation.
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3091-Camshaft sensor phase synchronization failure

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Segment speed sensor (Camshaft
speed sensor). If the engine has a defective Camshaft speed sensor it can run off the Increment speed sensor (Crank-
shaft speed sensor). Diagnostics is active if voltage is present at terminal 15 (Ignition On),, the current engine speed
is above 50 RPM, no error in the Crankshaft speed sensor is present and the sensor supply voltage ( 5 volts DC) is
not defective.
Cause:
The ECU has determined that there is no signal from the Camshaft speed sensor.
1. Faulty Camshaft speed sensor.

2. Camshaft speed sensor is not mechanically installed correctly.
Solution:

2. Remove Camshaft speed sensor connector DG6 Segm and inspect housing body/latch, pins and wiring harness
for damage or corrosion. Also, inspect connector portion of the Camshaft speed sensor.
good and sound electrical connection. Replace Camshaft speed sensor if damaged.

3. Operation: Resistance Check for Faulty Camshaft speed sensor.
Measure the resistance between the camshaft sensor connector pins 1 and 2. See test table below.

DG6 Segm (Pin 1) DG6 Segm (Pin 2)
4. Operation: Check Output of Camshaft speed sensor.
Make the following electrical tests in the table below. Reference the descriptions below to make the proper
electrical connections for each test type.
Single Ended Test Lead Connection Test (Standalone Camshaft speed sensor Test).
Remove Camshaft speed sensor connector DG6 Segm and connect the above mentioned special test lead to
the Camshaft speed sensor. Start the engine and measure the (AC) voltage using a multi-meter across the
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Remove Camshaft speed sensor connector DG6 Segm and connect the special test lead in-line with the sensor
and the engine wiring harness. Make sure that the signal polarity is not swapped during the connection process.
Start the engine and measure the (AC) voltage using a multi-meter across the breakout alligator clips from the
test leads. Use the test table below to determine the measurement results.
Note:
The engine will be running off the Crankshaft speed sensor during this test. The Camshaft speed sensor and the
Crankshaft speed sensor are exactly the same. These sensors may be swapped in this diagnostic procedure
to determine the functionality of the Camshaft speed sensor. A new set of error codes may be generated by the
ECU if sensors are swapped.

ended connection at low connector DG6 Segm (Pin connector DG6 Segm (Pin
RPM ( 1000 - 1100 RPM) 1) 2)
ended connection at high connector DG6 Segm (Pin connector DG6 Segm (Pin
RPM ( 2000 - 2200 RPM) 1) 2)
3. Voltage (AC) - In-line Camshaft speed, sensor Camshaft speed, sensor Approx. 1.5 - 2.8 volts
connection at low RPM ( connector DG6 Segm (Pin connector DG6 Segm (Pin (AC)
1000 - 1100 RPM) 1) 2)
4. Voltage (AC) - In-line Camshaft speed, sensor Camshaft speed, sensor Approx. 3 - 4.5 volts (AC)
connection at high RPM ( connector DG6 Segm (Pin connector DG6 Segm (Pin
2000 - 2200 RPM) 1) 2)
this type, ensure the Camshaft speed sensor was properly installed.
tions, proceed to step 5.
Perform continuity tests between connector DG6 Segm and connector 2 on engine wiring harness. Flex harness

1)
2)
nector 2 (Pin: 10) nector 2 (Pin: 9)
Vehicle Status (when removing connector 1). Key Off Engine Off.
Vehicle Status (when performing test). Key On Engine Off.
Vehicle Status (when replacing connector 1). Key Off Engine Off.
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1. Voltage ECU vehicle harness 1, Ground (engine block) Approx. 12 volts (DC)
(Pin: 2, 3, 8, 9, 40)
2. Continuity ECU vehicle harness 1, Ground (engine block) Approx. 0 - 0.10 ohms
(Pin: 5, 6, 10, 11)
A. If the voltages and ground paths are correct and the Camshaft speed sensor was not replaced on a prior
B. If the voltages and ground paths are correct and the Camshaft speed sensor was replaced on a prior diag-
nostic procedure of this type and the sensor mechanical alignment and spacing was verified, re-initialize
the ECU as if it was blank (new) and load the appropriate data-set.
has been resolved.
ation.
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3093-Offset Between Camshaft And Crankshaft - Outside

Boundaries
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) has reported an error with the phase relationship between the Increment speed sensor
(Crankshaft speed sensor) and the Segment speed sensor (Camshaft speed sensor). The engine will alternatively
use a redundant angular system which is based on the Crankshaft speed sensor. Diagnostics is active under these
conditions: 1) terminal 40 (Key On) is active, 2) current engine speed is above 50 RPM, 3) no error is reported for the
Crankshaft speed sensor and 4) sensor supply voltage ( 5 volts DC) is not defective .
Cause:
The ECU has determined that there is a phase relationship error between the Crankshaft speed sensor and the
Camshaft speed sensor.
1. Faulty Camshaft speed sensor or Crankshaft speed sensor.

2. Camshaft speed sensor or Crankshaft speed sensor are not mechanically installed correctly.
4. Faulty ECU, or ECU supply voltages or ground.
Solution:
2. Operation: Electrical and Sensor Mounting Inspection.
Remove Camshaft speed sensor connector DG6 Incr and Crankshaft speed sensor connector DG6 Incr and
inspect housing body/latch, pins and wiring harness for damage or corrosion. Also, inspect the connector portion
and mechanical mounting (seating) of the Camshaft speed sensor and Crankshaft speed sensor.
A. If damage is determined after careful inspection, repair wiring and/or replace connector parts to ensure
a good and sound electrical connection. Replace Camshaft speed sensor or Crankshaft speed sensor if
damaged.
B. If any of the sensors are not mounted correctly (loose, not seated properly, etc.), remount the sensors
taking special care to make sure it is properly seated (flush with sealing surface) and fastened.
C. If no damage is determined, proceed to step 3.

3. Operation: Resistance Test for Camshaft speed sensor.
Remove Camshaft speed sensor connector. Measure the resistance between the camshaft sensor pins 1 and
2. See test table below.

DG6 Incr (Pin 1) DG6 Incr (Pin 2)
B. If the resistance test does fall in the specified range, proceed to step 4.
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4. Operation: Resistance Test for Crankshaft speed sensor.

Measure the resistance between the crankshaft speed sensor pins 1 and 2. See test table below.

DG6 Incr (Pin 1) DG6 Incr (Pin 2)
A. If the resistance test does not fall in the specified range, replace Crankshaft speed sensor.
B. If the resistance test does fall in the specified range, proceed to step 5.
5. Operation: Check Crankshaft speed sensor Output Voltage and Harness Wiring.
Perform both (2) electrical tests defined below:
1) AC output voltage test for Crankshaft speed sensor

Remove Crankshaft speed sensor connector DG6 Incr and connect the Coolant/Fuel Temp Sensor test lead
in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during
the connection process. Start the engine and measure the (AC) voltage using a multi-meter across the breakout
alligator clips from the Coolant/Fuel Temp Sensor test lead. Use the table below to determine test parameters
and the measurement results.

connection at low RPM ( connector DG6 Incr (Pin 1) connector DG6 Incr (Pin 2)
1000 - 1100 RPM)
connection at high RPM ( connector DG6 Incr (Pin 1) connector DG6 Incr (Pin 2)
2000 - 2200 RPM)
2) Harness wiring continuity/shorts electrical test (Crankshaft speed sensor).

Remove and perform continuity tests between Crankshaft speed sensor connector DG6 Incr and ECU engine
harness connector 2 on engine wiring harness. Flex harness during test to check for any intermittent operation.
See test table below.

1)
2)
3. Shorts ECU engine harness con- ECU engine harness con- Open Circuit
A. If both electrical tests are successful, proceed to step 7.
B. If harness wiring continuity/shorts test was not successful, find and repair the damaged section(s) of the
wiring harness.
C. If the voltage test was not successful and the continuity/shorts test was successful, proceed to step 6.
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6. Operation: Crankshaft speed sensor alignment.

Check proper mechanical alignment and tooth spacing of the Crankshaft speed sensor. The spacing between
the trigger teeth and the sensor is critical for proper voltage output. Make sure that the sensor is seated properly
(flush with mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared.
A. If this fault code is still present and has not cleared, Replace Crankshaft speed sensor, being careful to
ensure the sensor's mechanical alignment and tooth spacing is correct and the sensor is seated properly.
B. If this fault code is still present and has not cleared, proceed to step 13.
7. Operation: Check Camshaft speed sensor Output Voltage and Harness Wiring.
Perform both (2) electrical tests defined below:
1) AC output voltage test for Camshaft speed sensor:

Remove Camshaft speed sensor connector DG6 Segm and connect the Coolant/Fuel Temp Sensor test lead
in-line with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during
the connection process. Start the engine and measure the (AC) voltage using a multi-meter across the breakout
alligator clips from the Coolant/Fuel Temp Sensor test lead. Use the table below to determine test parameters
and the measurement results.

1. Voltage (AC) - In-line Camshaft speed sensor Camshaft speed sensor Approx. - 1.5 - 2.8 volts
connection at low RPM ( connector DG6 Segm, connector DG6 Segm, (AC)
1000 - 1100 RPM) (Pin 1) (Pin 2)
2. Voltage (AC) - In-line Camshaft speed sensor Camshaft speed sensor Approx. - 3 - 4.5 volts
connection at high RPM ( connector DG6 Segm, connector DG6 Segm, (AC)
2000 - 2200 RPM) (Pin 1) (Pin 2)
2) Harness wiring continuity/shorts electrical test (Camshaft speed sensor).

Remove and perform continuity tests between Camshaft speed sensor connector DG6 Segm and ECU engine
harness connector. Flex harness during test to check for any intermittent operation. See test table below.

connector DG6 Segm (Pin: nector 2, (Pin: 10)
1)
connector DG6 Segm (Pin: nector 2, (Pin: 9)
2)
nector 2 (Pin: 10) nector 2, (Pin: 9)
A. If both electrical tests are successful, proceed to step 10.
B. If harness wiring continuity/shorts test was not unsuccessful, find and repair the damaged section(s) of
the wiring harness.
C. If the voltage test was not successful and the continuity/shorts test was successful, proceed to step 8.
8. Operation: Camshaft Position (CMP), Engine camshaft RPM B-07, sensor Alignment.
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Check proper mechanical alignment and tooth spacing of the Camshaft speed sensor. The spacing between
the trigger teeth and the sensor is critical for proper voltage output. Make sure that the sensor is seated properly
(flush with mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared.
A. If this fault code is still present and has not cleared, proceed to step 9.
9. Operation: Replace Camshaft speed sensor.
Replace the Camshaft speed sensor. Make sure that the proper mechanical alignment and tooth spacing is
correct. The spacing between the trigger teeth and the sensor is critical for proper voltage output. Make sure
that the sensor is seated properly (flush with mounting flange). After the sensor alignment is complete, check
to see if this fault code has cleared.
10. Operation: Replace Crankshaft speed sensor.
Replace the Crankshaft speed sensor. Make sure that the proper mechanical alignment and tooth spacing is
11. Operation: Swap the New Crankshaft speed sensor with the Old Camshaft speed sensor.
Replace the new Crankshaft speed sensor with the old Camshaft speed sensor. Make sure that the proper
mechanical alignment and tooth spacing is correct for both sensors. The spacing between the trigger teeth
and the sensor is critical for proper voltage output. Make sure that the sensors are seated properly (flush with
mounting flange). After the sensor alignment is complete, check to see if this fault code has cleared.
A. If this fault code still exists, proceed to step 12.

12. Operation: Replace Old Camshaft speed sensor.
Replace the old Camshaft speed sensor. When this is complete, both Crankshaft speed sensor and Camshaft
speed sensor will have been replaced. Make sure that the proper mechanical alignment and tooth spacing is
A. If this fault code still exists, proceed to step 13.

Vehicle Status (when removing the ECU vehicle harness connector 1): Key Off Engine Off.
Vehicle Status (when replacing ECU vehicle harness connector 1): Key Off Engine Off.
Using the product schematics for a reference, remove the ECU vehicle connector from the ECU and check for
voltage and continuity at the appropriate pins defined in the test table below.
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nector 1, (Pin: 2, 3, 8, 9,
40)
nector 1, (Pin: 5, 6, 10, 11)
B. If the voltages and ground paths are not correct, refer to schematics and determine root cause of power
and/or continuity problem(s).
14. Operation: Re-Initialize the ECU .
A. If the fault code did not clear, replace the ECU.

has been resolved.
ation.
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3095-Operating With Camshaft Sensor Only - Backup Mode

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) has reported an error with the monitoring of the Increment speed sensor (Crankshaft
speed sensor). In the case of a defective Crankshaft speed, sensor the engine can also be run alone with the Segment
speed sensor (Camshaft speed sensor) in a BACKUP mode. This operation, however, imposes a lot of restrictions
on the system since the precise position of the crankshaft can only be roughly estimated by the camshaft information.
In case the engine enters this BACKUP operation due to a crankshaft sensor error the fault path at hand is set.
Cause:
The ECU has determined that there are errors in the signal from the Crankshaft speed sensor and is currently oper-
ating in BACKUP mode. The engine is operating with input from only the Camshaft speed sensor.

Solution:

2. Remove Crankshaft speed sensor connector DG6 Incr and inspect housing body/latch, pins and wiring harness
for damage or corrosion. Also, inspect connector portion of the Crankshaft speed sensor.

3. Operation: Resistance Check for Faulty Crankshaft speed sensor.
Measure the resistance between the crankshaft speed sensor pins 1 and 2. See test table below.

DG6 Incr, (Pin 1) DG6 Incr, (Pin 2)
A. If the resistance test does not fall in the specified range, replace the Crankshaft speed sensor .
4. Operation: Check Output of Crankshaft speed sensor.
Make the following electrical tests in the table below. There will be (2) types of tests (in-line and single ended)
that will need to be performed which use the test lead labeled "Coolant/Fuel Temp Sensor" from the Tier II (NEF)
Diagnostic Repair Kit 380040185. Reference the descriptions below to make the proper electrical connections
for each test type.
Single Ended Test Lead Connection Test (Standalone Crankshaft speed sensor test):
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Remove Crankshaft speed sensor connector DG6 Incr and connect the above mentioned special test lead to
the Crankshaft speed sensor. Start the engine and measure the (AC) voltage using a multi-meter across the

Remove Crankshaft speed sensor connector DG6 Incr and connect the above mentioned special test lead in-line
with the sensor and the engine wiring harness. Make sure that the signal polarity is not swapped during the
connection process. Start the engine and measure the (AC) voltage using a multi-meter across the breakout
alligator clips from the test leads. Use the test table below to determine the measurement results.
Note:
The engine will be running off the Camshaft speed sensor during this test. The engine can also be very hard
to start when the Crankshaft speed sensor is disconnected. The ECU needs to see a few revolutions of the
camshaft to be able to use this information to start the engine. Another starting technique would be to have the
Crankshaft speed sensor connected in-line with the engine wiring harness with a breakout T connected to the
sensor.
The Crankshaft speed sensor and the Camshaft speed sensor are exactly the same. These sensors may be
swapped in this diagnostic procedure to determine the functionality of the Crankshaft speed sensor. A new set
of error codes may be generated by the ECU if sensors are swapped.

ended connection at low connector DG6 Incr, (Pin connector DG6 Incr, (Pin
RPM ( 1000 - 1100 RPM) 1) 2)
ended connection at high connector DG6 Incr, (Pin connector DG6 Incr, (Pin
RPM ( 2000 - 2200 RPM) 1) 2)
connection at low RPM ( connector DG6 Incr, (Pin connector DG6 Incr, (Pin
1000 - 1100 RPM) 1) 2)
connection at high RPM ( connector DG6 Incr, (Pin connector DG6 Incr, (Pin
2000 - 2200 RPM) 1) 2)
this type, ensure the sensor is installed properly.
tions, leave the connector disconnected and proceed to step 5.
Perform continuity tests between connector DG6 Incr and connector 2 on engine wiring harness. Flex harness

1)
2)
3. Shorts ECU engine harness con- ECU engine harness con- Open Circuit
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Using the product schematics for a reference, remove connector from the ECU and check for voltage and con-
tinuity at the appropriate pins defined in the test table below.

nector 1, (Pin: 2, 3, 8, 9,
40)
nector 1, (Pin: 5, 6, 10, 11)
A. If the voltages and ground paths are correct and the Crankshaft speed sensor was not replaced on a prior
B. If the voltages and ground paths are correct and the Crankshaft speed sensor was replaced on a prior
diagnostic procedure of this type and the sensor mechanical alignment and spacing was verified, re-ini-
tialize the ECU as if it was blank (new) and load the appropriate data-set.
C. If the voltages and ground paths are correct and the ECU was re initialized on a prior diagnostic of this
has been resolved.
ation.
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3096-CAN Bus: Bus Off error CAN A

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
CAN Data Link communications to the ECU have been lost. This fault code may be displayed with other CAN Data
Link fault messages. The Instrument Cluster will illuminate the Danger Lamp and will continually sound the
audible alarm. The Low Oil Pressure lamp will also turn on.
Cause:
CAN Data Link communications between the components on the CAN Bus and the ECU have been lost.

4. Faulty ECU
Solution:
last occurrence.
If three or more fault codes are active, 3334, 3339,1051 through 1059, this is an indication of a problem in the
CAN Data Link circuit, continue with this procedure. If one or two CAN Data Link fault codes are active, this is
an indication of an intermittent connection in the CAN circuit. Check all wires and connectors to verify they are
secure and free of damage, corrosion, abrasion or incorrect attachment.
RCPH11TLB007FAL 1
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A. CAN Data Link fault codes are not recorded again and are no longer ACTIVE. OK to return the machine
service.
B. CAN Data Link fault codes are present and ACTIVE. Go to Step 2.
RCPH11TLB034GAL 2
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(1) Switched battery to Diagnostic Port (6) CAN Bus to ECU

(2) Diagnostic Port X-002 (7) CAN Bus to Telematics (optional)
CAN Low X-498 pin D
(3) Diagnostic Port minus battery connec- (8) Switched battery to Telematics (optional)
tion Fuse F-001, 5 A
(4) CAN Bus to Trax Control (9) Drop harness
(5) CAN Bus to Instrument Cluster (10) Trunk harness
CAN Low X-029 pin 3
A. The CAN Data Link harness is not damaged and all connections are secure. Go to Step 3.
B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as
required. Go to Step 1 to confirm elimination of fault.
B. The resistance is less than 50 Ω. Go to Step 6.


A. All resistance measurements are greater than 20,000 Ω. Verify the ECU is powered and operational. Verify
that all minus battery and chassis ground connections to the CAN Bus modules are clean and secure.
Return to Step 1.
B. The resistance is less than 20,000 Ω. There is a short circuit in the CAN Data Link. Temporarily replace
the CAN Data Link wires and retest. Repair or replace the harness as required. Go to Step 1 to confirm
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nector pin D).
B. The resistance is less than 56 Ω there is a short circuit between the CAN High and CAN Low wires. Repair
or replace the harness as required. Go to test Step 1 to confirm elimination of the fault.
RCPH11TLB074FAL 3
CAN Low X-029 pin 3
Hig and CAN Low pins CAN High X-498 pin E
CAN Low X-498 pin D
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RCPH11TLB072FAL 4
CAN Low X-029 pin 3
CAN Low X-498 pin D
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3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has sensed that the Fuel Pressure sensor signal is too low. The test frequency of the
sensor is every 10 ms and if the signal is below 0.25 V for over 200 ms, the error is set. Once set the ECU will,
instead of using the peak rail pressure value of the last 10 ms and the current rail pressure, output a substitute value
from a curve (MAP) in the ECU depending on engine speed and injection quantity.
Cause:
The Rail Pressure sensor signal is too low.
1. Faulty Rail Pressure sensor.

2. Faulty circuit wiring, shorted to low source.
Solution:
1. Disconnect the engine sensor harness from the ECU at ECU engine connector 2 and place the Key switch in
the "On" position. Use a multi-meter check the voltage on the ECU from pin 13 to pin 12. There should be 5 V.
A. If there is 5 V reconnect ECU engine connector and continue with step 2
B. If there is less than 5 V, there is a failure inside the ECU, replace the ECU.
2. Disconnect the engine sensor harness from the Fuel Pressure sensor and place the Key switch in the "On"
position. Use a multi-meter check the voltage on the engine harness side of Fuel pressure sensor connector
RDS4 from pin 3 to pin 2. There should be 5 V.
A. If there is 5 V leave the Fuel pressure sensor connector disconnected and continue with step 3
B. If there is less than 5 V, there is a short to low source in the sensor circuit wiring, leave the Fuel pressure
sensor connector disconnected and continue with step 4
3. Disconnect the engine sensor harness from the ECU at ECU engine connector 2. Use a multi-meter to test for
continuity between the engine sensor harness side of ECU engine connector 2, pin 14 and ground and also
between Fuel pressure sensor connector RDS4 pin 1 and ground. There should be no continuity.
A. If there is continuity on either or both tests, there is a short to low source in the sensor signal wire, locate
and repair the short to low source.
B. If there is no continuity, either the sensor has failed or the ECU is faulty. Replace the common rail pressure
sensor and if the fault reoccurs reload the ECU software. If the fault reoccurs after replacing the sensor
and reloading software, replace the ECU.
4. Disconnect the engine sensor harness from the ECU at ECU engine connector 2. Use a multi-meter to test for
continuity between the engine sensor harness side of ECU engine connector 2, pin 13 and ground and also
between Fuel pressure sensor connector RDS4 pin 3 and ground. There should be no continuity.
A. If there is continuity, on either or both tests, there is a short to low source in the sensor source wire. Locate
and repair the short to low source.
B. If there is no continuity, on either or both tests, there is a short to low source in the sensor ground reference
wire. Locate and repair the short to low source.
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3104-Rail Pressure Relief Valve - Open

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that the Pressure Relief Valve (PRV) is open. Normally the fuel pressure
in the rail is regulated by the metering unit of the high pressure pump. However, if this component is malfunctioning
the rail pressure can rise to critical levels. For this reason the common rail has a Pressure Relief Valve (PRV) which is
a mechanical safety valve (no electrical connectors) that opens at a certain pressure level. An opening of the PRV is
detected by evaluating the gradient of the rail pressure (calculated by the ECU). If the PRV does not open on its own
after exceeding the pressure threshold it can also be forced open by a so-called 'kickoff' or pressure shock when the
metering valve of the high pressure fuel pump is set to maximum possible quantity. Once the PRV has been opened
it will remain open as long as the engine is running. A defective common rail pressure sensor, as judged by the ECU,
which evokes a kickoff (pressure shock) or a defect in an injection relevant component (small leak) can cause this
error to occur. This fault will only be cleared after an ECU reset.
1. Faulty Rail Pressure sensor, signal not plausible.

2. Faulty common rail fuel system, small leak.
Solution:
1. Use EST to check for other Rail Pressure sensor and injector (cylinder or bank) errors.
A. If Rail Pressure sensor or injector errors exist, follow troubleshooting procedure for existing Rail Pressure
sensor or injector error.
B. If no Rail Pressure sensor or injector errors exist, continue with step 2

2. Check common rail fuel system for leaks.
A. If common rail fuel system leak is found, repair as required.
B. If no common rail fuel system leak is found, continue with step 3

3. Visually inspect connector RDS4 and connector 2 for electrical integrity.
A. If damage or connectivity issues are discovered, repair, clean or replace as required.
B. If no damage or connectivity issues are discovered, replace Rail Pressure sensor and restart engine. If
error reoccurs continue with step 4
4. Visually inspect connector 2 for electrical integrity.
B. If no damage or connectivity issues are discovered, continue with step 5

5. Visually inspect injector connectors INJ1, INJ2, INJ3, INJ4, INJ5 AND INJ6 for electrical integrity.
B. If no damage or connectivity issues are discovered, continue with step 6

6. Reload ECU software.
A. If error reoccurs after trying to reload software, replace ECU.
B. If error has been resolved, continue with normal operation of machine.

47365539 08/07/2012
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3105-Rail Pressure Relief Valve - Pressure Shock Requested

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too high and the Pressure Relief
Valve (PRV) did not open. Normally the fuel pressure in the rail is regulated by the metering unit of the high pressure
pump. However, if this component is malfunctioning the rail pressure can rise to critical levels. For this reason the
common rail has a Pressure Relief Valve (PRV) which is a mechanical safety valve (no electrical connectors) that
opens at a certain pressure level. An opening of the PRV is detected by evaluating the gradient of the rail pressure
(calculated by the ECU). If the PRV does not open on its own after exceeding the pressure threshold it can also be
forced open by a so-called 'kickoff' or pressure shock when the metering valve of the high pressure fuel pump is set to
maximum possible quantity. Rail pressure in excess of 148500 kPa (21538.1 psi) for 1 s evokes a kickoff (pressure
shock) request by the ECU. If the pressure shock (kickoff) does not immediately open the PRV, this error will occur.
This fault will only be cleared after an ECU reset.
1. Faulty ECU, improper data set.

2. Faulty PRV, mechanical valve does not function.
Solution:
1. Use the EST to flash the ECU with the appropriate data set.
A. If the error reoccurs, replace the PRV.
B. If the error does not reoccur, return the combine to service.

47365539 08/07/2012
55.DTC / 227
3106-Rail Pressure Relief Valve - Did Not Open After Pressure

Shock
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that the Pressure Relief Valve (PRV) did not open after a pressure
shock (kickoff). Normally the fuel pressure in the rail is regulated by the metering unit of the high pressure pump.
However, if this component is malfunctioning the rail pressure can rise to critical levels. For this reason the common
rail has a Pressure Relief Valve (PRV) which is a mechanical safety valve (no electrical connectors) that opens at a
certain pressure level. An opening of the PRV is detected by evaluating the gradient of the rail pressure (calculated
by the ECU). If the PRV does not open on its own after exceeding the pressure threshold it can also be forced open
by a so-called 'kickoff' or pressure shock when the metering valve of the high pressure fuel pump is set to maximum
possible quantity. Rail pressure in excess of 148500 kPa (21538.1 psi) for 1 s evokes a kickoff (pressure shock)
request by the ECU. If the pressure shock (kickoff) request is present longer than 2 s and did not immediately open
the PRV, this error will occur. This fault will only be cleared after an ECU reset.
1. Faulty ECU, improper data set.

2. Faulty PRV, mechanical valve does not function.
Solution:
1. Use the EST to flash the ECU with the appropriate data set.
A. If the error reoccurs, replace the PRV.
B. If the error does not reoccur, return the combine to service.

47365539 08/07/2012
55.DTC / 228
3107-Metering unit output short circuit to battery on low side

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that a short to high source circuit condition exists in the fuel high pres-
sure pump low side circuit. The metering unit of the fuel high pressure pump regulates the pressure in the common
rail. The metering unit is closed-loop controlled by both main relay 1 (high side) and a low side power stage (Main
Relay 1 is an electronic control circuit within the ECU, providing source voltage to devices external to the ECU. The
low side power stage works in conjunction with the Main Relay 1 source, providing sensing and current limiting for the
circuit). The monitoring at low side is stopped if a short circuit to ground at the high side (main relay 1) is detected or it
is switched off for some reason. Failure detection of is only possible if the low side power stage is switched on. With
the current settings, the monitoring is shut off during after-run. This error is the result of the power stage hardware
report of 'short circuit to battery' (on the low side of the metering unit) longer than 0.0 (zero) milliseconds and once
the permanent error is detected the power stage is switched off.
Cause:
Fuel high pressure pump circuit is shorted to a high source.
1. Faulty fuel high pressure pump control circuit, shorted to a high source.
Solution:

2. Disconnect the Engine Injector harness from the ECU at connector 3 and place the Key switch in the "On"
position. Use a multi-meter to test for voltage from the Engine Injector harness side of connector 3, pin 10 to
chassis ground. There should be no voltage.
A. If there is voltage, locate and repair the short to the voltage source.
B. If there is no voltage, continue with step 3

3. Disconnect the Engine Injector harness from the fuel high pressure pump at connector ZME and use a multi-
meter to check the resistance of the fuel high pressure pump solenoid coil. There should be a small amount of
resistance.
A. If there is a small amount of resistance, try reloading the ECU software and if the error reoccurs, replace
the ECU.
B. If there is no resistance, the fuel high pressure pump solenoid coil has failed, replace the solenoid.
has been resolved.
ation.
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3110-Rail Pressure Sensor Monitoring - Signal Above Range

Maximum
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has sensed that the Rail Pressure sensor offset signal is too high. This test is performed
during after-run and is aborted if the Key switch is switched "On" during after-run. During after-run the measured raw
value of the Rail Pressure sensor is compared to the atmospheric pressure sensor within the ECU. To ensure that the
rail pressure has depressurized sufficiently to atmospheric levels after engine shutoff, the monitoring is released only
if the delay time determined by the rail pressure dependent curve (ECU pre-programmed data) has elapsed and the
fuel temperature is above -0.04 °C (31.93 °F). If the raw value of the rail pressure sensor exceeds 0.65 V over 100
milliseconds during after-run, this error is set and will reset if the value goes below the limit for over 100 milliseconds.
Cause:
The Rail Pressure sensor after-run signal is too high.
1. Faulty circuit wiring or electrical connection.

2. Faulty sensor.
Solution:
1. Use EST to check for other Rail Pressure sensor errors.
A. If Rail Pressure sensor errors exist, follow troubleshooting procedure for existing Rail Pressure sensor
error.
B. If no Rail Pressure sensor errors exist, continue with step 2

2. Disconnect the Engine Sensor harness from the ECU at connector 2 and from the Rail Pressure sensor at
connector RDS4. Use a multi-meter to check for continuity from the Engine Sensor harness side of connector
2, pin 13 to the Engine Sensor harness side of connector RDS4, pin 3. There should be continuity.
A. If there is continuity, leave the connectors disconnected and continue with step 3
B. If there is no continuity, there is an open circuit condition in the sensor source wire. Locate and repair the
open circuit condition.
3. Use a multi-meter to check for continuity from the Engine Sensor harness side of connector 2, pin 14 to the
Engine Sensor harness side of connector RDS4, pin 2. There should be continuity.
B. If there is no continuity, there is an open circuit condition in the sensor ground reference wire. Locate and
repair the open circuit condition.
B. If there is no continuity, there is an open circuit condition in the sensor signal wire. Locate and repair the
5. Visually inspect both connectors for electrical integrity.
B. If no damage or connectivity issues are discovered, replace the sensor.

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3111-Rail Pressure Sensor Monitoring - Signal Below Range

Minimum
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has sensed that the Rail Pressure sensor offset signal is too low. This test is performed
during after-run and is aborted if the Key switch is switched "On" during after-run. During after-run the measured raw
value of the Rail Pressure sensor is compared to the atmospheric pressure sensor within the ECU. To ensure that the
rail pressure has depressurized sufficiently to atmospheric levels after engine shutoff, the monitoring is released only
if the delay time determined by the rail pressure dependent curve (ECU pre-programmed data) has elapsed and the
fuel temperature is above -0.04 °C (31.93 °F). If the raw value of the rail pressure sensor is below 0.35 V over 100
milliseconds during after-run, this error is set and will reset if the value goes above the limit for over 100 milliseconds.
Cause:
The Rail Pressure sensor after-run signal is too low.
1. Faulty circuit wiring or electrical connection.

2. Faulty sensor.
Solution:
1. Use EST to check for other Rail Pressure sensor errors.
A. If Rail Pressure sensor errors exist, follow troubleshooting procedure for existing Rail Pressure sensor
error.
B. If no Rail Pressure sensor errors exist, continue with step 2

2. Disconnect the Engine Sensor harness from the ECU at connector 2 and from the Rail Pressure sensor at
connector RDS4. Use a multi-meter to check for continuity from the Engine Sensor harness side of connector
2, pin 13 to the Engine Sensor harness side of connector RDS4, pin 3. There should be continuity.
B. If there is no continuity, there is an open circuit condition in the sensor source wire. Locate and repair the
B. If there is no continuity, there is an open circuit condition in the sensor ground reference wire. Locate and
repair the open circuit condition.
B. If there is no continuity, there is an open circuit condition in the sensor signal wire. Locate and repair the
5. Visually inspect both connectors for electrical integrity.
B. If no damage or connectivity issues are discovered, replace the sensor.

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3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has sensed that the Fuel Pressure sensor signal is too high. The test frequency of the
sensor is every 10 ms and if the signal is in excess of 4.86 V for over 200 ms, the error is set. Once set the ECU will,
instead of using the peak rail pressure value of the last 10 ms and the current rail pressure, output a substitute value
from a curve (MAP) in the ECU depending on engine speed and injection quantity.
Cause:
The Fuel Pressure sensor signal is too high.
1. Faulty Fuel Pressure sensor.

2. Faulty circuit wiring, shorted to high source.
Solution:
1. Disconnect the engine sensor harness from the ECU at ECU engine connector 2 and place the Key switch in
the "On" position. Using a multi-meter check the voltage on the ECU engine connector from pin 13 to pin 12.
There should be 5 V.
A. If there is 5 V reconnect ECU engine connector and continue with step 2
B. If there is greater than 5 V, there is a failure inside the ECU, replace the ECU.
2. Disconnect the engine sensor harness from the Rail Pressure sensor and place the Key switch in the "On"
position. Use a multi-meter check the voltage on the engine harness side of Rail pressure sensor connector
RDS4 from pin 3 to pin 2. There should be 5 V.
A. If there is 5 V leave the Rail pressure sensor connector disconnected and continue with step 3
B. If there is greater than 5 V, there is a short to high source in the sensor circuit wiring, leave the Rail pressure
sensor connector RDS4 disconnected and continue with step 4
3. Disconnect the engine sensor harness from the ECU at ECU engine connector 2. Use a multi-meter test for
voltage between the engine sensor harness side of ECU engine connector 2, pin 14 and ground and also be-
tween Rail pressure sensor connector RDS4, pin 1 and ground. There should be no voltage.
A. If there is voltage on either or both tests, there is a short to high source in the sensor signal wire, locate
and repair the short to high source.
B. If there is no voltage, either the sensor has failed or the ECU is faulty. Replace the Rail Pressure sensor
and if the fault reoccurs reload the ECU software. If the fault reoccurs after replacing the sensor and
reloading software, replace the ECU.
4. Disconnect the engine sensor harness from the ECU at ECU engine connector 2. Use a multi-meter test for
voltage between the engine sensor harness side of ECU engine connector 2, pin 13 and ground and also be-
tween Rail pressure sensor connector RDS4, pin 3 and ground. There should be no voltage.
A. If there is voltage, on either or both tests, there is a short to high source in the sensor source wire. Locate
and repair the short to high source.
B. If there is no voltage, on both tests, there is a short to high source in the sensor ground reference wire.
Locate and repair the short to high source.
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3118-ECM 12V sensor supply voltage high

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTICE: Check alternator output voltage, if above 14 V, troubleshoot charging system before proceeding.
NOTE: Besides the 3 independent 5V voltage supplies the ECU also provides a 12V supply for the sensors. This 12V
supply is monitored to ensure it remains within a certain range. This is done by using an analog input of the ECU.
The lower and upper thresholds depend on the battery voltage.
Cause:

Solution:
rence.

2. Check input voltage.
(1) Turn ignition OFF. Disconnect ECU connector B. Inspect pins, wiring and connectors for damage, abrasion,
corrosion or incorrect attachment.
A. NOT OK – Check fuses, replace as needed. Return to Step 1 to confirm elimination of fault. If fuses check
good go to Step 3.
3. Check circuit
47365539 08/07/2012
55.DTC / 233
RCPH10TLB302AAF 3
(1) Fuse block

(2) Diagnostic port
(1) Inspect fuse block connections and wiring for damage, abrasion, corrosion or incorrect attachment.
(2) Measure the resistance from ECU connector X-461, pins 1, 3, 5, and 28 to fuse F-038 and F-037. The
resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent
condition.
A. NOT OK – If circuit is open, check circuit splice on front console harness. Repair or replace the harness
as required. Return to Step 1 to confirm elimination of fault.
4. Replace the engine control unit.
(1) Remove and replace engine control unit.
for assistance.
47365539 08/07/2012
55.DTC / 234
3119-ECM 12V sensor supply voltage low

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTICE: Check alternator output voltage. Troubleshoot charging system before proceeding.
Cause:

Solution:
rence.

2. Check input voltage.
(1) Turn ignition OFF. Disconnect ECU connector X-461. Inspect pins, wiring and connectors for damage, abra-
good go to Step 3.
3. Check circuit.
47365539 08/07/2012
55.DTC / 235
RCPH10TLB302AAF 3
(1) Fuse block

(2) Diagnostic port
(1) Inspect fuse block connections and wiring for damage, abrasion, corrosion or incorrect attachment.
(2) Measure the resistance from ECU connector X-461, pins 1, 3, 5, and 28 to fuse F-037 and F-038. The
resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent
condition.
A. NOT OK – If circuit is open, check splice on front console harness. Repair or replace the harness as
for assistance.
47365539 08/07/2012
55.DTC / 236
3137-Metering Unit - Open Load

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that an open circuit condition exists in the Pump control valve (Metering
Unit - High Pressure Pump Regulator solenoid/valve) circuit. The metering unit of the fuel high pressure pump regu-
lates the pressure in the common rail. The metering unit is controlled by both main relay 1 high side and a low side
power stages (Main Relay 1 is an electronic control circuit within the ECU used to provide fixed and variable control
signals to devices external to the ECU). The monitoring at low side is stopped if a short circuit to ground at the high
side (main relay 1) is detected or it is switched off for some reason. Failure detection of an over current condition is
only possible if the low side power stage is switched on and the open circuit condition only if it is switched off. With
report of an 'open load' in the metering unit longer than 200 milliseconds.
Cause:
Pump control valve circuit is open.
1. Faulty Pump control valve, open solenoid coil.

2. Faulty circuit, open conductor.
Solution:
1. Disconnect the ECU cylinder connector from the ECU at connector 3. Use a multi-meter to check the resistance
on the Engine Injector harness side of connector 3, from pin 9 to pin 10. There should be approximately 3.2 Ω.
A. If there is approximately 3.2 Ω, check for other ECU errors that could inhibit operation of the ECU main
relay 1 circuit and follow those troubleshooting procedures.
B. If there is a high resistance reading, leave connector 3 disconnected and continue with step 2
2. Disconnect the Engine Injector harness from the Pump control valve at connector ZME. Use a multi-meter to
check the resistance of the Pump control valve solenoid coil. There should be approximately 3.2 Ω.
A. If there is approximately 3.2 Ω, leave connector ZME disconnected and continue with step 3
B. If there is a high resistance reading, replace the Pump control valve solenoid.
3. Use a multi-meter to check for continuity from the Engine Injector harness side of connector ZME, pin 1 to the
Engine Injector harness side of connector 3, pin 10. There should be continuity.
B. If there is no continuity, locate and repair the break in the wire.

Engine Injector harness side of connector 3, pin 9. There should be continuity.
A. If there is continuity, try reloading the ECU software and if the error reoccurs, replace the ECU.
B. If there is no continuity, locate and repair the break in the wire.
47365539 08/07/2012
55.DTC / 237
3139-Metering Unit Signal Range Check - Signal Too High

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that it is sensing a voltage greater than 5.2 V. The metering unit of the
fuel high pressure pump regulates the pressure in the common rail.
Cause:
Fuel high pressure pump circuit is shorted to a high source.
1. Faulty fuel high pressure pump control circuit, shorted to a high source.
2. Faulty fuel high pressure pump
Solution:
B. If the error is no longer present or is in an inactive state, return machine to proper operation.
2. Disconnect the wiring harness from the ECU. Place the Key switch in the "On" position. Use a multi-meter to
test for voltage from the wiring harness side connector pin 15 to chassis ground. There should be no voltage.
A. If there is voltage, locate and repair the short to the voltage source.
B. If there is no voltage, continue with step 3

3. Disconnect the wiring harness from the fuel high pressure pump. Use a multi-meter to check the resistance of
the fuel high pressure pump solenoid coil. There should be a small amount of resistance.
A. If there is a small amount of resistance, try reloading the ECU software and if the error reoccurs, replace
the ECU.
B. If there is no resistance, the fuel high pressure pump solenoid coil has failed, replace the solenoid.
47365539 08/07/2012
55.DTC / 238
3140-Metering Unit Signal Range Check - Signal Too Low

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that the sensing voltage is less than 0.0 V. The metering unit of the
fuel high pressure pump regulates the pressure in the common rail.
Cause:
Fuel high pressure pump circuit is shorted to a low source.
1. Fuel high pressure pump control circuit, shorted to a low source.

2. Faulty Fuel high pressure pump
3. Faulty control module.
Solution:
2. Disconnect the wiring harness from the ECU module. Use a multi-meter to check for continuity from the wiring
harness side of ECU connector pin 15 to chassis ground. There should be no continuity.
A. If there is continuity, continue with step 3
B. If there is no continuity, try reloading the ECU software and if the error reoccurs, replace the ECU.
3. Disconnect the wiring harness from the Fuel high pressure pump. Use a multi-meter to check for continuity on
the fuel high pressure pump connector pins 1 and 2 to chassis ground. There should be no continuity on either
pin to ground.
A. If there is continuity on either pin, the fuel high pressure pump solenoid coil has failed, replace the solenoid.
B. If there is no continuity on either pin, there is a short to low source in the wiring harness, locate and repair
the short to ground.
47365539 08/07/2012
55.DTC / 239
3141-Set point of fuel volume flow through metering unit is lower

than calculated limit
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that there is either Fuel System Leakage or the Metering Unit (High
Pressure Pump Regulator solenoid/valve) is jammed in closed position. The rail pressure is monitored by various fault
paths during active pressure control by the metering unit. The fault path at hand detects a leakage of fuel by monitoring
the set-point current used to control the metering unit. The monitoring is only active if the high pressure governor (High
Pressure Pump Regulator solenoid/valve) is operating in closed loop control, the rail pressure governor deviation is
within the range +/- 5000 kPa (725.2 psi) and the monitoring has not been inhibited by other faults. If the metering
unit current control set-point current is below a calculated minimum limit over 2.5 seconds this error will occur. [This
limit is calculated from various curves, maps and correction factors established by the ECU]. This error is the result
of an inaccurate Rail pressure sensor or defective high pressure pump in the high pressure system or Metering unit
reflux too low, fuel system leakage, or metering unit jammed in the closed position in the low pressure system.
47365539 08/07/2012
55.DTC / 240
3146-Water detected in fuel

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECU has detected excess water in the fuel system. This message is sent to the Instrument Cluster via the CAN
Bus. The Instrument Cluster will illuminate the amber warning light while the is active fault.
Cause:
Fault Code 1022 is a CAN Data Link message from the ECU to the Instrument Cluster. This fault code is displayed
on the Instrument Cluster to warn the operator that the ECU has detected excess water in the fuel system. Refer to
Solution:
1. Drain the fuel filter of excess water.
B. If the error is no longer present or is in an inactive state, return the machine to service.
(1) Inspect the ECU and the Water In Fuel Sensor connections. All connections should be secure, tight, free of
corrosion, abrasion and damage.
(2) Inspect the harness from the ECU to the WIF Sensor. Verify that the harness is free of damage, corrosion,
abrasion or incorrect attachment.
RCPH11TLB086FAL 1
3. Disconnect the WIF sensor
(2) Disconnect the WIF sensor.
47365539 08/07/2012
55.DTC / 241
(3) Turn the key switch ON. Monitor the EST diagnostic screen. The fault code should no longer be active.
A. The fault code is not active while the sensor is disconnect and the fault code is active while the sensor is
connected. Temporarily replace the WIF sensor and retest. Go to Step 1 to confirm elimination of the fault.
B. The fault code is active while the sensor is disconnected. Go to Step 4.

4. Disconnect the WIF signal wire at the ECU
(2) Disconnect the WIF sensor signal wire, X-461 pin 30.
A. The fault code is not active while the signal wire is disconnect and the fault code is active when the signal
wire is connected. The WIF sensor signal wire is shorted to chassis ground or minus battery. Temporarily
replace the signal wire and retest. Go to Step 1 to confirm elimination of the fault.
B. The fault code is active while the WIF sensor signal wire is disconnected. Temporarily repalce the ECU
and retest. Go to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 242
3147-Oil Temperature Too High

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
temperature sensing function of the device. This error resulted from a plausibility check against the oil temperature
being too high. The ECU will prohibit the any plausibility check when there are Analog to Digital Converter (ADC)
signal errors detected on the Oil temp / press sensor.
Cause:
The Oil temp / press sensor is reporting an abnormally high oil temperature to the ECU.

2. Faulty electrical wiring and / or connections.
4. Faulty oil lubrication or coolant system.
Solution:
1. Operation: Check for Coolant System Faults.
Use EST to check for errors associated with coolant temperature.

Also, check the coolant level. A faulty coolant system that is operating above normal temperatures could cause
a high oil temperature since the engine has an integrated oil / coolant heat exchanger.
A. If the coolant level is low, add the appropriate amount and type of coolant.
B. If any of the errors exist, resolve the existing error. Then determine if this error has also been resolved.
C. If none of the errors exist, continue with step 2.

2. Operation: Check for Oil Pressure Faults.
Use EST to check for errors associated with oil pressure.

Also, check the engine oil level on the sump dipstick. A low pressure oil delivery system, could result in high oil
temperatures.
A. If the oil level is low, add the appropriate amount and type of oil.
B. If any of the errors exist, resolve the existing error. Then determine if this error has also been resolved.
C. If none of the errors exist, continue with step 3.


47365539 08/07/2012
55.DTC / 243


5. Operation: Oil temp / press sensor Test
Remove ODFT connector and test resistance of Oil temp / press sensor using the table of resistance vs. temp.
below. Approximate the engine oil temperature when performing test. Use a multi-meter between pins 1 and 2.
Engine Oil Temperature Resistance Value (between pins 1 and 2)

-40 °C (-40 °F) 70 kOhm
-20 °C (-4 °F) 25 kOhm
0 °C (32 °F) 7.5 kOhm
20 °C (68 °F) 4.5 kOhm
40 °C (104 °F) 1.5 kOhm
60 °C (140 °F) 750 ohms
80 °C (176 °F) 550 ohms
100 °C (212 °F) 320 ohms
120 °C (248 °F) 130 ohms
Remove and perform continuity tests between connectors ODFT and ECU on engine wiring harness. Flex har-
ness during test to check for any intermittent operation. See test table below.

Use product schematic for a reference, remove connector from the ECU and check for voltage and continuity
Important Note:
47365539 08/07/2012
55.DTC / 244

1. Voltage 1, (Pin 2, 3, 8, 9, 40) Ground (engine block) Approx. 12 volts
2. Continuity 1, (Pin 5, 6, 10, 11) Ground (engine block) Approx. 0 - 0.10 ohms
47365539 08/07/2012
55.DTC / 245
3171-Fuel rail system pressure too low

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too low. The rail pressure is
monitored by various fault paths during active pressure control by the metering unit. The fault path at hand detects if
the rail pressure has fallen below a minimum pressure threshold. The monitoring is only active if the high pressure
governor is operating in closed loop control and the monitoring has not been inhibited by other faults. If the rail pres-
sure is below the engine speed dependent limit from a curve, established by the ECU, over 2.5 seconds this error will
occur. This error is the result of a leak in the high or low pressure side of the fuel rail system. On the high pressure
side check for worn or stuck open injector, worn high pressure pump or leaking pressure relief valve. On the low
pressure side check for low fuel pressure before or after the gear pump, clogged fuel filter or leakage.
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3172-Fuel rail system pressure too high

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too high. The rail pressure is
monitored by various fault paths during active pressure control by the metering unit. The fault path at hand detects
if the rail pressure has exceeded a maximum pressure threshold. The monitoring is only active if the high pressure
sure exceeds the maximum pressure 150000 kPa (21755.7 psi) over 1 second, this error will occur.
Cause:
The Fuel Rail/System Pressure is too high.
1. Faulty high pressure pump regulator solenoid/valve, stuck open.

2. Pressure too high, low pressure side.
Solution:
1. Check for high pressure pump regulator (solenoid/valve) errors.
A. If high pressure pump regulator (solenoid/valve) errors exist, follow troubleshooting procedure for existing
high pressure pump regulator (solenoid/valve) error.
B. If no high pressure pump regulator (solenoid/valve) errors exist, locate and repair high pressure condition
in low pressure side of fuel system.
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3173-Rail Pressure Governor Deviation Below Min. Limit for Speed

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This fault has been generated due to the injector control pressure is too low. Check for more specific failures related
to the rail pressure system. If no other faults are active, check the rail injectors are not damaged. Also, check for any
rail or injector leakages. If any damages or leakages are found, repair or replace necessary components.
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3174-Rail Pressure Governor Deviation Exceeded Max. Limit

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:

Solution:
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3175-Fuel system leak detected - large leak

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
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3176-Fuel delivery exceeded threshold for pressure in overrun

mode
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that the Metering Unit (High Pressure Pump Regulator solenoid/valve)
has excessively opened to reach the desired Rail pressure. The rail pressure is monitored by various fault paths
during active pressure control by the metering unit. The fault path at hand detects an excessive leakage of fuel by
monitoring the set-point value of the fuel volume flow through the metering unit during overrun. The monitoring is
only active if the high pressure governor (High Pressure Pump Regulator solenoid/valve) is operating in closed loop
control, the engine is in overrun condition, the fuel injection quantity is zero and the monitoring has not been inhibited
by other faults. If the set-point value of the rail pressure governor for the fuel volume flow through the metering unit
exceeds an upper limit over 2.5 seconds this error will occur. [This limit is interpolated from the rail pressure dependent
curve, established by the ECU]. This error is the result of leakage in the high pressure section; injection nozzle stuck
in open position, worn or defective high pressure pump, worn injector, leaking pressure relief valve. or leakage in the
low pressure system; 'Zero delivery' is not active in metering unit (excessive leakage in metering unit).
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3188-Cylinder 1 Warning - Open Load

Context:
The Engine control unit (ECU) has determined that an open circuit condition exists in the Cylinder 1 injector circuit. A
the failure corresponding to the matched pattern is output. If an error message doesn't match any pattern the defect is
treated as an unclassifiable error. Monitoring is performed once per camshaft revolution. This error is the result of an
open circuit failure being present for over 3 camshaft revolutions. As a result of this error an individual cylinder or bank
is shut off, based on parameters established in the ECU. Certain parameters, as currently applied, are permanent
(without a healing possibility, once tested by switching on the component to see if the defect is still present) and others
evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
The Engine control unit (ECU) has determined that there is a fault associated with the current monitoring of the Cylin-
der 1 injector output power driver stage.
1. Faulty Cylinder 1 injector solenoid windings.

2. Faulty electrical wiring, open circuit (damaged wiring).
Solution:

2. Carefully disconnect the engine harness from the ECU at the cylinder connector 3. Use a multi-meter to check
the resistance, on the engine harness side of the cylinder connector 3, between pins 4 and 13. There should
be 0.4 - 0.5 Ω.
A. If the resistance is within range, the ECU may have failed. Try reloading the ECU software and if the fault
reoccurs, replace the ECU .
B. If the resistance was significantly greater than maximum range, continue with step 3
3. Disconnect the engine cylinder harness from the injector (valve) cover at connector VC1. Use a multi-meter to
check resistance on the injector (valve) cover side of connector from pin 3 to pin 4. There should be 0.4 - 0.5 Ω.
A. If a small amount of resistance exists, there is open circuit condition in the engine cylinder harness between
the ECU cylinder harness connector 3 and the Cylinder 1 /2 valve cover connector VC1. Locate and repair
the broken conductor.
INJ1. Use a multi-meter to check resistance, on the Cylinder 1 injector, from terminal 1 to terminal 2. There
should be 0.4 - 0.5 Ω.
A. If the resistance is within range, there is an open circuit condition in the injector harness, between injector
connector and ECU cylinder connector . Locate and repair the broken conductor.
B. If the resistance was significantly greater than maximum range, the Cylinder 1 injector solenoid coil has
failed. Replace the injector.
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has been resolved.
ation.
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3192-Cylinder 2 - Open Load

Context:
The engine control unit (ECU) has determined that an open circuit condition exists in the Cylinder 2 injector circuit. A
(without a healing possibility, once tested by switching on the component to see if the defect is still present). and
others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
Cylinder 2 injector output power driver stage.
1. Faulty injection valve or open solenoid windings.

Solution:

resistance, on the engine injector harness side of connector 3, between pins 6 and 11. There should be 0.4 -
0.5 Ω.
reoccurs, replace the ECU.
check resistance on the injector (valve) cover side of connector VC1 from pin 1 to pin 2. There should be 0.4 -
0.5 Ω.
A. If a small amount of resistance exists, there is open circuit condition in the engine injector harness between
connector 3 and connector VC1. Locate and repair the broken conductor.
terminal 1 (high side ring terminal) Use a multi-meter to check resistance, on the Cylinder 2 injector, from terminal
1 to terminal 2. There should be 0.4 - 0.5 Ω.
A. If the resistance is within range, there is an open circuit condition in the injector harness, between con-
nector VC1 and connector INJ2. Locate and repair the broken conductor.
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has been resolved.
ation.
47365539 08/07/2012
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Context:
Cause:

Solution:

0.5 Ω.
0.5 Ω.
nector 3 and connector VC2. Locate and repair the broken conductor.
47365539 08/07/2012
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has been resolved.
ation.
47365539 08/07/2012
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Context:
Cause:

Solution:

0.5 Ω.
0.5 Ω.
nector VC2 and connector INJ4. Locate and repair the broken conductor.
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has been resolved.
ation.
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3210-Bank 1 - General Short Circuit To Injector Cable

NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to accurately measure resistance
. The DMM must measure to a resolution of 0.1 ohms. The required measurements are as low as 0.4 ohms (typical
injector solenoid coil resistance is 0.4 - 0.5 Ω) and any DMM inaccuracies will cause the technician to inaccurately
troubleshoot.
NOTE: Ensure the DMM's test lead resistance is considered when measuring resistance. Touch the leads together
on the lowest Ohms scale and record the resistance measurement. Subtract this value from all future resistance
measurements.
Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 1 (Group A, Cylinders
1, 2, & 3). A power stage component energizes the injection system transistors while observing the current flow
in the high-side and low-side switching branch by sensing resistors. Deviations from the expected current flow are
detected as specific errors by the component and reported to the ECU. Error messages are configured to contain
information on performed injections, same bank cylinder errors, bank specific errors and cylinder specific errors. The
configured error message is compared to applicable error patterns, and the failure matching the pattern is output. If an
error message doesn't match a pattern the defect becomes an unclassifiable error. Monitoring is performed once per
camshaft revolution. This error is a result of a general short circuit of the high side to battery or ground over 4 camshaft
revolutions. This error shuts off an individual cylinder or bank, based on ECU parameters. Certain parameters, as
currently applied, are permanent; there is no healing possibility after testing: switching on the component to ascertain
the defect's presence. Others evoke an irreversible or reversible engine shut off.
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of an injector
output power driver stage in Bank 1.

2. Faulty electrical wiring, short high side to high source, low side or ground (damaged wiring harness).
Solution:

2. Disconnect the engine injector harness from the ECU at connector 3. Use a DMM to check the resistance on
the engine injector harness side of connector 3.
From:
1. Pin 4 to pin 13
2. Pin 11 to pin 6
3. Pin 5 to pin 12
There should be 0.4 - 0.5 Ω.
A. If the resistance was within range, leave ECU connector 3 disconnected and continue to step 8.
B. If the resistance was below range, record the pin numbers and continue to step 3.
3. Use a DMM to check for continuity on the engine injector harness side of connector 3, from pins 4, 11, and 5 to
A. If there was continuity, record the pin number and continue to step 4.
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B. If there was no continuity, continue to step 6.

4. Disconnect the engine injector harness from the injector (valve) cover at connector VC1 and connector VC2.
Use a DMM to check for continuity on the injector (valve) cover side of connector :
From:
1. Connector VC1 pin 4, if recorded pin in Step 3 was pin 4, to chassis ground
3. Connector VC2 pin 4, if recorded pin in Step 3 was pin 5, to chassis ground.
There should not be continuity.
A. If there was continuity, leave connector VC1 and connector VC2 disconnected. Continue to step 5.
B. If there was no continuity, there is a short to ground condition in the engine injector harness between
connector VC1 pin 4 or 1, and ECU connector 3 pin 4, or 11
or between connector VC2 pin 4 and ECU connector 3, pin 5. Locate and repair the grounded conductor.
5. Remove the injector (valve) cover and disconnect the injector harness from the injector:
For:
1. Cylinder #1 injector at connector INJ1 terminal 1 (high side ring terminal) if recorded pin in Step 3
was pin 4
2. Cylinder #2 injector at connector INJ2 if recorded pin in Step 3 was pin 11
Use a DMM to check for continuity, on the injector, from terminal 1 to chassis ground. There should not be
continuity.
A. If there is continuity, the injector solenoid coil has failed: replace the injector.
B. If there is no continuity, there is a short to ground condition in the injector circuit, between connector INJ1
(if recorded pin in Step 3 was pin 4), or connector INJ2 (if recorded pin in Step 3 was pin 11), and connector
VC1, pin 4, or 1 and ECU connector 3, pin 4, or 11
or connector VC2 and connector INJ3 (if recorded pin in Step 3 was pin 5) and ECU connector 3, pin 5.
Locate and repair the grounded conductor.
6. Disconnect the engine injector harness from the injector cover at connector VC1 and VC2. Use a DMM to
measure the resistance on the injector cover side of connector :
From:
1. VC1, pin 4 to 3, if recorded pins in Step 2 were pins 4 and 13
2. VC1, pin 2 to 1, if recorded pins in Step 2 were pins 11 and 6
3. VC2, Pin 3 to 4, if recorded pins in Step 2 were pins 5 and 12
connector VC1, pin 4, or 1, and ECU connector 3, pin 13, or 6
or connector VC2, pin 4 and ECU connector 3 pin 12. Locate and repair the short circuit.
B. If the resistance was below range, continue to step 7

For:
1. Cylinder #1 injector at connector INJ1, terminal 1 (high side ring terminal), if recorded pins in Step
2 were pins 4 and 13
2. Cylinder #2 injector at connector INJ2, if recorded pins in Step 2 were pin 11 and 6
3. Cylinder #3 injector at connector INJ3, if recorded pins in Step 2 were pins 5 and 12
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Use a DMM to check for continuity, on the injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 Ω.
nector INJ1 or INJ2 and connector VC1 pin 3, or 2, ECU connector 3 pin 13, or 6
or connector INJ3 and connector VC2 pin 3, ECU connector 3, pin 12. Locate and repair the shorted
conductors.
B. If the resistance was below range, the injector solenoid coil has failed. Replace the injector.
8. Use a DMM to check for continuity, on the engine injector harness side of ECU connector 3, from pins 4, 11,
and 5 to all other populated pins in connector 3. There should not be continuity.
A. If there is continuity, record the pin numbers and use to locate and repair the shorted conductors.
B. If there is no continuity, the ECU may have failed. Attempt reloading the ECU software. If the fault reoc-
curs, replace the ECU.
has been resolved.
ation.
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3211-Bank 1 - Injector cable Short Circuit Low Side To Ground

Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 1 (Group A, Cylinders
Cause:
injector output power driver stage in Bank 1.
1. Faulty injection valve (solenoid coil shorted to ground).

2. Faulty electrical wiring, short low side to ground (damaged wiring).
Solution:

2. Carefully disconnect the engine injector harness from the ECU at connector 3. Use a multi-meter to check for
continuity, on the engine injector harness side of ECU connector 3 from pins 13, 6 and 12 to chassis ground.
A. If there is continuity on any of the pins to chassis ground, record the pin number and continue with step 3.
B. If there is no continuity, the ECU may have failed. Try reloading the ECU software and if the fault reoccurs,
replace the ECU.
3. Disconnect the engine injector harness from the injector (valve) cover at connector VC1 and VC2. Use a multi-
meter to check for continuity, on the injector (valve) cover side of connector VC1 from pin 3, if recorded pin in
Step 2 was pin 13, or pin 2, if recorded pin in Step 2 was pin 6
or connector VC2 pin 3, if recorded pin in Step 2 was pin 12, to chassis ground. There should not be continuity.
A. If there was continuity to chassis ground, leave connector VC1 and VC2 disconnected, and continue with
step 4
B. If there was no continuity to chassis ground, there is a short to ground condition in the engine injector
harness between connector VC1 pin 3 or 2 and ECU connector 3 pin 13 or 6
or between connector VC2, pin 3 and ECU connector 3, pin 12. Locate and repair the grounded conductor.
INJ1 terminal 2 (low side ring terminal), if recorded pin in Step 2 was pin 13, or disconnect the injector harness
from the Cylinder #2 injector at connector INJ2, if recorded pin in Step 2 was pin 6 or disconnect the injector
harness from the Cylinder #3 injector at connector INJ3, if recorded pin in Step 2 was pin 12. Use a multi-meter
to check for continuity, on the injector, from terminal 2 to chassis ground. There should not be continuity.
A. If there is continuity, the injector solenoid coil has failed, replace the injector.
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B. If there is no continuity, there is a short to ground condition in the injector circuit, between connector INJ1,
if recorded pin in Step 2 was pin 13, or connector INJ2 if recorded pin in Step 2 was pin 6 and connector
VC1 pin 2 or 3 and ECU connector 3 pin 6 or 13
or connector INJ3, if recorded pin in Step 2 was pin 12. and connector VC2, pin 3 and ECU connector 3,
pin 12. Locate and repair the grounded conductor.
has been resolved.
ation.
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3213-Bank 1 - Unclassifiable Error

Context:
The engine control unit (ECU) has determined that an unclassified error exists in an injector cable in Bank 1 (Group
A, Cylinders 1, 2, & 3). A power stage component energizes the injection system transistors and simultaneously
observes the current flow in the high-side and low-side switching branch by sensing resistors. If there is a deviation
from the expected current flow the component detects specific errors and reports them to the ECU. This error message
is then rearranged so it holds information on performed injections, errors of cylinders on the same bank, bank specific
errors and cylinder specific errors. The rearranged error message is then compared to applicable error patterns and
if there is a match the failure corresponding to the matched pattern is output. If an error message doesn't match
any pattern the defect is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution.
This error is the result of an unclassified error being present over 9 camshaft revolutions. As a result of this error an
is still present), and others evoke an irreversible or reversible shut off of the engine to be executed.
Cause:
stage in Bank 1.

Solution:

2. Visually check the electrical integrity of the injector circuits in Bank 1 (Inspect connector housing body/latch,
pins and wiring harness for damage or corrosion).
B. If no damage is determined, the ECU may have failed. Try reloading the ECU software and if the fault
has been resolved.
ation.
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3218-Bank 2 - General Short Circuit On Injector Cable

NOTE: This diagnostic procedure requires a good quality Digital Multi-meter (DMM) to accurately measure resistance
. The DMM must measure to a resolution of 0.1 ohms. The required measurements are as low as 0.4 ohms (typical
injector solenoid coil resistance is 0.4 - 0.5 Ω) and any DMM inaccuracies will cause the technician to inaccurately
troubleshoot.
NOTE: Ensure the DMM's test lead resistance is considered when measuring resistance. Touch the leads together
on the lowest Ohms scale and record the resistance measurement. Subtract this value from all future resistance
measurements.
Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 2 (Group B, Cylinders
Cause:
The Engine Control Unit (ECU) has determined that there is a fault associated with the current monitoring of an injector
output power driver stage in Bank 2.

2. Faulty electrical wiring, short high side to high source, low side or ground (damaged wiring harness).
Solution:

2. Disconnect the engine injector harness from the ECU at connector 3. Use a DMM to check the resistance on
the engine injector harness side of connector 3.
From:
1. Pin 14 to pin 3
2. Pin 16 to pin 1
3. Pin 15 to pin 2
A. If the resistance was within range, leave connector 3 disconnected and continue to step 8.
B. If the resistance was below range, record the pin numbers and continue to step 3.
3. Use a DMM to check for continuity on the engine injector harness side of connector 3, from pins 3, 1, and 2 to
A. If there was continuity, record the pin number and continue to step 4.
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B. If there was no continuity, continue to step 6.

4. Disconnect the engine injector harness from the injector (valve) cover at connector VC3 and connector VC2.
Use a DMM to check for continuity on the injector (valve) cover side of connector :
From:
3. Connector VC2 pin 2, if recorded pin in Step 3 was pin 3, to chassis ground.
A. If there was continuity, leave connector VC3 and connector VC2 disconnected. Continue to step 5.
B. If there was no continuity, there is a short to ground condition in the engine injector harness between
connector VC3 pin 2 or 3, and ECU connector 3, pin 1 or 2
or between connector VC2 pin 2 and ECU connector 3 pin 3. Locate and repair the grounded conductor.
For:
1. Cylinder #4 injector at connector INJ4 terminal 1 (high side ring terminal) if recorded pin in Step 3
was pin 3
Use a DMM to check for continuity, on the injector, from terminal 1 to chassis ground. There should not be
continuity.
A. If there is continuity, the injector solenoid coil has failed: replace the injector.
B. If there is no continuity, there is a short to ground condition in the injector circuit, between connector INJ5
(if recorded pin in Step 3 was pin 1), or connector INJ6 (if recorded pin in Step 3 was pin 2), and connector
or connector VC2 pin 2 and connector INJ4 (if recorded pin in Step 3 was pin 3) and ECU connector 3 pin
3. Locate and repair the grounded conductor.
6. Disconnect the engine injector harness from the injector cover at connector VC3 and VC2. Use a DMM to
measure the resistance on the injector cover side of connector :
From:
1. VC3 pin 1 to 2, if recorded pins in Step 2 were pins 2 and 15
2. VC3 pin 3 to 4, if recorded pins in Step 2 were pins 1 and 16
3. VC2 Pin 1 to 2, if recorded pins in Step 2 were pins 3 and 14
connector VC3 pin 2 or 3, and ECU connector 3 pin 16 or 15
or connector VC2 pin 2 and ECU connector 3 pin 14. Locate and repair the short circuit.
B. If the resistance was below range, continue to step 7.

For:
1. Cylinder #4 injector at connector INJ4 terminal 1 (high side ring terminal), if recorded pins in Step
2 were pins 3 and 14
2. Cylinder #5 injector at connector INJ5, if recorded pins in Step 2 were pin 1 and 16
3. Cylinder #6 injector at connector INJ6, if recorded pins in Step 2 were pins 2 and 15
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Use a DMM to check for continuity, on the injector, from terminal 1 to terminal 2. There should be 0.4 - 0.5 Ω.
nector INJ5, or INJ6 and connector VC3 pin 4 or 1, ECU connector 3 pin 16 or 15
or connector INJ4 and connector VC2 pin 1 and, ECU connector 3 pin 14. Locate and repair the shorted
conductors.
B. If the resistance was below range, the injector solenoid coil has failed. Replace the injector.
8. Use a DMM to check for continuity, on the engine injector harness side of connector 3, from pins 3, 1, and 2 to
all other populated pins in ECU connector 3. There should not be continuity.
A. If there is continuity, record the pin numbers and use to locate and repair the shorted conductors.
B. If there is no continuity, the ECU may have failed. Attempt reloading the ECU software. If the fault reoc-
curs, replace the ECU.
has been resolved.
ation.
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3219-Bank 2 - Injector Cable Short Circuit Low Side To Ground

Context:
The Engine Control Unit (ECU) has determined a short circuit exists in an injector cable in Bank 2 (Group B, Cylinders
Cause:
injector output power driver stage in Bank 2.
1. Faulty injection valve (solenoid coil shorted to ground).

2. Faulty electrical wiring, short low side to ground (damaged wiring).
Solution:

2. Carefully disconnect the engine injector harness from the ECU at connector 3. Use a multi-meter to check for
continuity, on the engine injector harness side of ECU connector 3 from pins 16, 15 and 14 to chassis ground.
A. If there is continuity on any of the pins to chassis ground, record the pin number and continue with step 3.
B. If there is no continuity, the ECU may have failed. Try reloading the ECU software and if the fault reoccurs,
replace the ECU.
3. Disconnect the engine injector harness from the injector (valve) cover at connector VC3 and VC2. Use a multi-
meter to check for continuity, on the injector (valve) cover side of connector VC3 from pin 4, if recorded pin in
Step 2 was pin 16, or pin 1, if recorded pin in Step 2 was pin 15
or connector VC2 pin 1, if recorded pin in Step 2 was pin 14, to chassis ground. There should not be continuity.
A. If there was continuity to chassis ground, leave connector VC3 and VC2 disconnected, and continue with
step 4
B. If there was no continuity to chassis ground, there is a short to ground condition in the engine injector
harness between connector vc3 pin 4 or 1 and ECU connector 3 pin 16 or 15
or between connector VC2 pin 1 and ECU connector 3 pin 14. Locate and repair the grounded conductor.
INJ4 terminal 2 (low side ring terminal), if recorded pin in Step 2 was pin 14, or disconnect the injector harness
from the Cylinder #5 injector at connector INJ5, if recorded pin in Step 2 was pin 16 or disconnect the injector
harness from the Cylinder #3 injector at connector INJ6, if recorded pin in Step 2 was pin 15. Use a multi-meter
to check for continuity, on the injector, from terminal 2 to chassis ground. There should not be continuity.
A. If there is continuity, the injector solenoid coil has failed, replace the injector.
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B. If there is no continuity, there is a short to ground condition in the injector circuit, between connector INJ5,
if recorded pin in Step 2 was pin 16, or connector INJ6 if recorded pin in Step 2 was pin 15 and connector
or connector INJ4, if recorded pin in Step 2 was pin 14. and connector VC2 pin 1 and ECU connector 3
pin 14. Locate and repair the grounded conductor.
has been resolved.
ation.
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3221-Bank 2 - Unclassifiable Error

Context:
The engine control unit (ECU) has determined that an unclassified error exists in an injector cable in Bank 2 (Group
B, Cylinders 4, 5, & 6). A power stage component energizes the injection system transistors and simultaneously
observes the current flow in the high-side and low-side switching branch by sensing resistors. If there is a deviation
from the expected current flow the component detects specific errors and reports them to the ECU. This error message
is then rearranged so it holds information on performed injections, errors of cylinders on the same bank, bank specific
errors and cylinder specific errors. The rearranged error message is then compared to applicable error patterns and
if there is a match the failure corresponding to the matched pattern is output. If an error message doesn't match
any pattern the defect is treated as an unclassifiable error. Monitoring is performed once per camshaft revolution.
This error is the result of an unclassified error being present over 9 camshaft revolutions. As a result of this error an
Cause:
stage in Bank 2.

Solution:

2. Visually check the electrical integrity of the injector circuits in Bank 2 (Inspect connector housing body/latch,
pins and wiring harness for damage or corrosion).
B. If no damage is determined, the ECU may have failed. Try reloading the ECU software and if the fault
has been resolved.
ation.
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3227-Injection Processor Error - Internal Reset/Clock Loss/Voltage

Too Low
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has sensed a problem with the internal supply voltage for Fuel Injector Group “A”, the
fault path for errors in the power stage component of the unit injection system. The power stage monitors itself and
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If an internal reset or parity
error is present longer than 3 camshaft revolutions , this error will occur. As a result of this error an individual cylinder
or bank is shut off. This shut off is currently applied to be permanent without a healing possibility by switching on the
component to see if the defect is still present. With either an irreversible or reversible shut off of the engine being
executed. The reason for this failure is a defective ECU. If the fault doesn't reset or reoccurs, replace the ECU.
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3228-Injection Processor Error - Unlocked/Initialization Error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If an internal program flow
error exists for longer than 3 camshaft revolutions , this error will occur. As a result of this error an individual cylinder
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3229-Injection processor error - stop engine

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If the YSEL signal is not
inverted as requested during injection for longer than 3 camshaft revolutions , this error will occur. As a result of this
error an individual cylinder or bank is shut off. This shut off is currently applied to be permanent without a healing
possibility by switching on the component to see if the defect is still present. With either an irreversible or reversible
shut off of the engine being executed. The reason for this failure is a defective ECU. If the fault doesn't reset or
47365539 08/07/2012
55.DTC / 274

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If the power stage compo-
nent On Time-out is present for at least one cylinder for longer than 3 camshaft revolutions , this error will occur. As a
result of this error an individual cylinder or bank is shut off. This shut off is currently applied to be permanent without
a healing possibility by switching on the component to see if the defect is still present. With either an irreversible or
reversible shut off of the engine being executed. The reason for this failure is a defective ECU. If the fault doesn't
reset or reoccurs, replace the ECU.
47365539 08/07/2012
55.DTC / 275

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has sensed a problem with the internal supply voltage for Fuel Injector Group “B”, the
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. An internal reset or parity
error present longer than 3 camshaft revolutions, will produce this error. As a result of this error an individual cylinder
47365539 08/07/2012
55.DTC / 276

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has sensed a problem with the internal supply voltage for Fuel Injector Group “B”, the
reports detected errors to the ECU. Monitoring is performed once per camshaft revolution. If an internal program flow
error exists for longer than 3 camshaft revolutions , this error will occur. As a result of this error an individual cylinder
47365539 08/07/2012
55.DTC / 277

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has sensed a problem with the internal supply for Fuel Injector Group “B”, the fault
path for errors in the power stage component of the unit injection system. The power stage monitors itself and reports
detected errors to the ECU. Monitoring is performed once per camshaft revolution. If the power stage component
On Time-out is present for at least one cylinder for longer than 3 camshaft revolutions , this error will occur. As a
result of this error an individual cylinder or bank is shut off. This shut off is currently applied to be permanent without
a healing possibility by switching on the component to see if the defect is still present. With either an irreversible or
reversible shut off of the engine being executed. The reason for this failure is a defective ECU. If the fault doesn't
reset or reoccurs, replace the ECU.
47365539 08/07/2012
55.DTC / 278

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected that injection time is too long. The sum of all torque-forming energizing
times of an individual cylinder exceeds the limit, calculated from the map (depending on the engine speed and the
time since the overrun monitoring is active) for more than 100 test events (test frequency every 10 ms). When the
engine is in overrun operation the monitoring becomes active and the current injection energizing time is compared
with a maximum permissible time limit. If the limit is exceeded an ECU recovery (reset ) is triggered and if the error
reoccurs in the same driving cycle, the torque-determining power stages are irreversibly shut off. The basic idea is
that the operator reacts to an unintentional torque increase, caused by a malfunction of the ECU, by releasing the
accelerator pedal (reducing engine speed) which causes the engine to enter the overrun operation mode. Overrun
monitoring is only released if various conditions are met, such as no accelerator pedal activation, no activated cruise
control, no intervention of the vehicle dynamic control or gearbox control is present, etc. This failure could be the
result of electronic disturbances, a requested torque increase via tester, the wrong application of injection relevant
parameters, or a defective ECU. If this failure persists, the ECU may need to be replaced.
47365539 08/07/2012
55.DTC / 279
3235-Number of Injections Limited - by Charge Balance

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The number of injections is greater than normal injections released for current engine speed. This fault will correct
when the number of injections are in range with engine speed. To correct this fault, try re-flashing the software. If that
does not correct the fault, replace the ECU.
47365539 08/07/2012
55.DTC / 280
3236-Number of Injections Limited - by Quantity Balance

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The number of injections is greater than normal injections released for current engine speed. This fault will correct
when the number of injections are in range with engine speed. To correct this fault, try re-flashing the software. If that
does not correct the fault, replace the ECU.
47365539 08/07/2012
55.DTC / 281
3237-Number of Injections Limited - by Software

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This fault has occurred because the desired number of injections is greater than maximum number of injections per
cycle, depending on battery voltage and power requirements for energizing. Check battery voltage, and check power
supply of booster banks. If battery voltage is low, charge battery and recheck. If battery does not hold a charge,
replace the battery. If the power supply of the booster banks is insufficient, check for other faults present. Resolve
those faults.
47365539 08/07/2012
55.DTC / 282
3238-Communication error of CJ940 processor

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected an internal communications error. Internal communications between
the micro-controller and each CJ940 module (peripheral integrated circuit) via the SPI bus is monitored cyclically
every 20 milliseconds by evaluating the corresponding communication error flag which is provided by the hardware
encapsulation. For every test an error counter is increased or decreased in steps of one. If the error counter for
defective SPI buss communications reaches or exceeds a value of 5 this error becomes active and will reset once the
error counter is equal to or below the value of 0 (zero). This error is caused by electrical disturbances or an internal
defect of the ECU. If failure remains present, replace the ECU.
47365539 08/07/2012
55.DTC / 283
3242-Engine Controller (Locked) Recovery Occurred

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected, during system start up, a hardware or configuration problem. This triggers
an ECU recovery (reset of the CPU - Central Processing Unit) that is stored as protected. During a fresh ECU start
up different hardware tests are performed. If the error remains present even after reset, the software remains in the
boot-block and the driving software is not processed. If three recoveries are triggered within 4 seconds an irreversible
shut off of the system is carried out and the ECU is classified as permanently defective. In this case no error entry is
possible. If, however, the error leading to recovery is not detected repeatedly and the system is allowed to start up,
one of three recovery errors becomes active depending on the visibility of the recovery. This error can be the result
of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error occurs
repeatedly, reprogram the ECU and if the error remains, replace the ECU.
47365539 08/07/2012
55.DTC / 284
3243-Engine Controller Recovery (Suppressed) - Recovery

Occurred
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
an ECU recovery (reset of the CPU - Central Processing Unit) that is not stored. During a fresh ECU start up different
hardware tests are performed. If the error remains present even after reset, the software remains in the boot-block
and the driving software is not processed. If three recoveries are triggered within 4 seconds an irreversible shut
off of the system is carried out and the ECU is classified as permanently defective. In this case no error entry is
possible. If, however, the error leading to recovery is not detected repeatedly and the system is allowed to start up,
one of three recovery errors becomes active depending on the visibility of the recovery. This error can be the result
of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error occurs
repeatedly, reprogram the ECU and if the error remains, replace the ECU.
47365539 08/07/2012
55.DTC / 285
3244-Soft Controller Reset

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
an ECU recovery (reset of the CPU - Central Processing Unit) that is visible in the error memory. During a fresh ECU
start up different hardware tests are performed. If the error remains present even after reset, the software remains
in the boot-block and the driving software is not processed. If three recoveries are triggered within 4 seconds an
irreversible shut off of the system is carried out and the ECU is classified as permanently defective. In this case no
error entry is possible. If, however, the error leading to recovery is not detected repeatedly and the system is allowed
to start up, one of three recovery errors becomes active depending on the visibility of the recovery. This error can be
the result of electronic disturbances, various hardware defects (ECU internal) or configuration problems. If this error
occurs repeatedly, reprogram the ECU and if the error remains, replace the ECU.
47365539 08/07/2012
55.DTC / 286
3245-Engine Controller - Watchdog Not Plausible

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected a fault in the internal monitoring circuitry. The ECU contains a CPU (central
processing unit) and other microprocessor based circuitry one of which serves as a monitoring module (watchdog).
These two components communicate via the internal communications network (SPI-Bus). Both devices mutually
monitor one another for correct functioning. The watchdog initiates a query / response communication with the CPU,
which responds by starting a "command test" (test of the correct functioning of important processor commands) and
"program flow control" (monitors the correct execution of code segments of the monitoring). From the results of these
two procedures the response to the watchdog is composed. If this response does not correspond to the expected
value, an error counter is incremented. The CPU periodically sends incorrect responses (regarding response time
and value, respectively) as result of the watchdog query / response. The CPU then monitors if the above mentioned
counter is incremented or decremented in accordance with the incorrect or correct response. If the behavior of the
counter is implausible, a second counter is incremented. This monitoring process is executed every 80 ms. This error
is the result of one of the counters exceeding a count of 5 and will reset if both counters contain a value less than 5.
If the error exists only temporarily, it can be ignored and deleted in the fault memory. If the error is permanent, engine
injection will not be allowed and the ECU must be replaced.
47365539 08/07/2012
55.DTC / 287
3246-Shutoff Paths During Initialization - Watchdog

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected an internal watchdog error. The ECU comprises redundant shutoff paths
(SOP) which deactivate all power stages relevant to injection if certain internal ECU errors are detected. The defects
which trigger SOP are the watchdog, over voltage and under voltage errors. In order to test the correct functioning
of the SOP procedure, every path is activated during ECU initialization and followed by activation of the fuel injection
power stage. Since the SOP is active, no injection should occur as it is blocked if the SOP procedure functions
properly. During a successful redundant SOP test an open circuit (no current flow) should be detected. The SOP test
can only be carried out if no errors, such as short circuits of the injection power stage, have been detected previously.
This fault is detected if injection occurred although internal SOP of the watchdog was active. If the failure remains
after ECU initialization, replace the ECU.
47365539 08/07/2012
55.DTC / 288
3247-Shutoff Paths Failed During Initialization - Supply Voltage

Too High
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected that the internal supply voltage is too high. The ECU comprises redundant
shut-off paths (SOP) which deactivate all power stages relevant to injection if certain internal ECU errors are detected.
The defects which trigger SOP are the watchdog, over voltage and under voltage errors. In order to test the correct
functioning of the SOP procedure, every path is activated during ECU initialization and followed by activation of the
fuel injection power stage. Since the SOP is active, no injection should occur as it is blocked if the SOP procedure
functions properly. During a successful redundant SOP test an open circuit (no current flow) should be detected. The
SOP test can only be carried out if no errors, such as short circuits of the injection power stage, have been detected
previously. This fault is detected if injection occurred although internal SOP of the over-voltage was active. If the
failure remains after ECU initialization, replace the ECU.
47365539 08/07/2012
55.DTC / 289
3248-Shutoff Paths During Initialization - Supply Voltage Too Low

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected that the internal supply voltage is too low. The ECU comprises redundant
shutoff paths (SOP) which deactivate all power stages relevant to injection if certain internal ECU errors are detected.
The defects which trigger SOP are the watchdog, over voltage and under voltage errors. In order to test the correct
functioning of the SOP procedure, every path is activated during ECU initialization and followed by activation of the
fuel injection power stage. Since the SOP is active, no injection should occur as it is blocked if the SOP procedure
functions properly. During a successful redundant SOP test an open circuit (no current flow) should be detected. The
SOP test can only be carried out if no errors, such as short circuits of the injection power stage, have been detected
previously. This fault is detected if injection occurred although internal SOP of the under-voltage was active. If the
failure remains after ECU initialization, replace the ECU.
47365539 08/07/2012
55.DTC / 290
3252-Controller Watchdog - SPI Communication Failure

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected an internal (SPI Bus) communication failure. The central processing
unit (CPU) and monitoring module (watchdog) contained with in the ECU, communicate with each other via the SPI
bus. Both devices mutually monitor each other for correct functioning. If, however, the SPI communication between
them fails this monitoring is impaired and an error counter is incremented. If the error counter exceeds 2 over two
20 ms (two tests) checks, this fault is activated. Communication status is checked autonomously by the SPI driver
component every 20 ms and reports a detected error to the ECU. This error initiates ECU recovery (reset). If the ECU
functions correctly after recovery, the SPI error is temporary and can be ignored and deleted from fault memory. If
the SPI error is permanent and the ECU does not leave boot-block, the ECU needs to be replaced.
47365539 08/07/2012
55.DTC / 291
3253-ADC Monitoring - Reference Voltage Too Low

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
1. Internal ECU error
Solution:
rence.
(1). Use the Electronic Service Tool to clear all fault codes.
(2). To check for fault code: Start and operate machine.

2. Reset Engine Control Unit (ECU).
(1). Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
A. Return to Step 1 to confirm elimination of fault.
B. NOT OK - Go to Step 3.
3. Replace ECU (Engine Control Unit).
(1). Remove and replace ECU (Engine Control Unit).
for assistance.
47365539 08/07/2012
55.DTC / 292
3254-ADC Monitoring - Reference Voltage Too High

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 293
3255-ADC Monitoring Test Impulse Error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 294
3256-ADC Monitoring Queue Error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 295
3258-HS power stage hardware reports 'short circuit to battery'

longer than 500 ms.
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:

2. Faulty reading from ECU.
Solution:
rence.

2. Measure the voltage on the high side line.
(1) Disconnect the ECU connector X-461.
(3) Measure the voltage from X-461 pin 27 to chassis ground. The voltage should be less than 0.5 V. Wiggle
RCPH11TLB100FAL 1
Schematic Legend
(1) Unswitched battery from starter (7) Neutral signal from FNR switch
(2) Start Relay, K-016 (8) Relay coil ground
(3) Neutral Relay, K-015 (9) High side
ECU Crank Enable signal, X-461 pin 27
(4) ECU Start Relay, K-017 (10) Low side
(5) Start signal to starter solenoid (11) Start Relay Ground
(6) Key switch ON
47365539 08/07/2012
55.DTC / 296
A. The voltage is less than 0.5 V. Temporarily replace the ECU and retest. Return to Step 1 to confirm elimi-
nation of fault.
B. The voltage is greater than 12 V. There is a short circuit to an external voltage. Repair or replace the
harness as required. Return to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 297
3259-HS power stage hardware reports 'short circuit to ground'

longer than 100 ms.
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:

Solution:
rence.

2. Measure the resistance of the high side line to chassis ground.
(2) Disconnect the ECU connector X-461. Disconnect the ECU Start relay.
Ω. Wiggle the harness during measurement to reveal an intermittent condition.
RCPH11TLB100FAL 1
Schematic Legend
(6) Key switch ON
47365539 08/07/2012
55.DTC / 298
A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU and retest. Return to Step 1 to
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the harness. Repair or
replace the harness as required. Return to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 299
3260-LS power stage hardware reports 'open load' longer than

100 ms
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
1. Open circuit in the wiring harness.

2. Faulty relay. .
3. Faulty ECU.
Solution:
rence.

2. Measure the resistance of the relay.
(2) Disconnect the ECU Start relay.
(3) Measure the resistance across terminals 85 and 86. The resistance should be less than 100 Ω.
A. The resistance is less than 100 Ω. Go to Step 3.
B. The resistance is greater than 100 Ω. Temporarily replace the relay and retest. Return to Step 1 to confirm
3. Measure the resistance through the relay drive lines.
(1) Turn the key switch OFF. Disconnect the ECU connector X-461.
(2) Measure the resistance between X-461 pin 27 and the connector for relay terminal 85. The resistance should
(2) Measure the resistance between X-461 pin 53 and the connector for relay terminal 86. The resistance should
A. The resistance is less than 10 Ω. Temporarily replace the ECU and retest. Return to Step 1 to confirm
B. The voltage is greater than 10 Ω. There is an open circuit in the wiring. . Repair or replace the harness
as required. Return to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 300
3261-LS power stage hardware reports 'short circuit to battery' or

'excess temperature' longer than 100 ms.
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
1. Wiring or circuits shorted to chassis ground.

Solution:
rence.

2. Measure the voltage on the low side line.
(3) Measure the voltage from X-461 pin 53to chassis ground. The voltage should be less than 0.5 V. Wiggle the
RCPH11TLB100FAL 1
Schematic Legend
(6) Key switch ON
47365539 08/07/2012
55.DTC / 301
nation of fault.
B. The voltage is greater than 12 V. There is a short circuit to an external voltage. Repair or replace the
47365539 08/07/2012
55.DTC / 302
3262-LS power stage hardware reports 'short circuit to ground'

longer than 100 ms.
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:

Solution:
rence.

2. Measure the resistance of the low side line to chassis ground.
(2) Disconnect the ECU connector X-461. Disconnect the ECU Start relay.
RCPH11TLB100FAL 1
Schematic Legend
(6) Key switch ON
47365539 08/07/2012
55.DTC / 303
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the harness. Repair or
replace the harness as required. Return to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 304
3263-Busoff in CAN C
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 305
3265-Energizing time exceeds limit of over run monitoring, injection

time too long
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected that injection time is too long. The sum of all torque-forming energizing
times of an individual cylinder exceeds the limit, calculated from the map (depending on the engine speed and the
time since the overrun monitoring is active) for more than 100 test events (test frequency every 10 ms). When the
engine is in overrun operation the monitoring becomes active and the current injection energizing time is compared
with a maximum permissible time limit. If the limit is exceeded an ECU recovery (reset ) is triggered and if the error
reoccurs in the same driving cycle, the torque-determining power stages are irreversibly shut off. The basic idea is
that the operator reacts to an unintentional torque increase, caused by a malfunction of the ECU, by releasing the
accelerator pedal (reducing engine speed) which causes the engine to enter the overrun operation mode. Overrun
monitoring is only released if various conditions are met, such as no accelerator pedal activation, no activated cruise
control, no intervention of the vehicle dynamic control or gearbox control is present, etc. This failure could be the
result of electronic disturbances, a requested torque increase via tester, the wrong application of injection relevant
parameters, or a defective ECU. If this failure persists, the ECU may need to be replaced.
47365539 08/07/2012
55.DTC / 306
3266-Error in engine speed check, speed signal not plausible

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that the speed signal is not plausible. In order to execute an overrun
monitoring, which checks if the injection energizing time is below a certain limit during overrun, the information of the
current engine speed is required. As the overrun monitoring is executed in layer 2 of the ECU monitoring concept (i.e.
function monitoring) in order to monitor the safety-relevant signal paths of the operational layer (layer 1, application
software) a redundant engine speed is additionally calculated in layer 2, independent of the engine speed information
of layer 1. If the absolute value of the deviation between engine speed (layer 1) and redundant segment speed (layer
2) exceeds 320 RPM over 800 ms (test frequency is every 40 ms), while the redundant segment speed is above 1000
RPM this error is activated, which triggers an ECU recovery (reset). If this failure persists after ECU re-initialization,
replace the ECU.
47365539 08/07/2012
55.DTC / 307
3278-Engine Controller Supply Voltage Too High

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTE: Check alternator output voltage, if above 16 volts refer to electrical trouble shooting section before proceeding.
See engine repair manual for electrical schematic information.
Cause:
1. Faulty alternator output.

Solution:
rence.

pins 2, 4, and 6). The voltage should be between 11.5 V and . 13 V.
for assistance.
47365539 08/07/2012
55.DTC / 308

47365539 08/07/2012
55.DTC / 309
3279-Engine Controller Internal Supply Voltage Too Low

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:

2. Faulty wiring.
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 310

47365539 08/07/2012
55.DTC / 311
3280-Sensor Supply Voltage 1 - High

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:

Solution:
rence.

(1) Turn ignition OFF. Disconnect Engine Control Unit (ECU) connector B from engine controller.
A. NOT OK – Voltage is too high. Troubleshoot the charging system. Return to Step 1 to confirm elimination
of fault.
B. NOT OK – Voltage is to low. Verify battery voltage. Check fuses and wiring to ECU. Return to Step 1 to
47365539 08/07/2012
55.DTC / 312
C. OK – Go to Step 3.
for assistance.
47365539 08/07/2012
55.DTC / 313
3281-Sensor Supply Voltage 1 - Low

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:

2. Faulty wiring.
Solution:
rence.

of fault.
47365539 08/07/2012
55.DTC / 314
for assistance.
47365539 08/07/2012
55.DTC / 315

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:

2. Faulty wiring.
Solution:
rence.

of fault.
47365539 08/07/2012
55.DTC / 316
for assistance.
47365539 08/07/2012
55.DTC / 317

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:

2. Faulty wiring.
Solution:
rence.

of fault.
47365539 08/07/2012
55.DTC / 318
for assistance.
47365539 08/07/2012
55.DTC / 319

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:

2. Faulty wiring.
Solution:
rence.

of fault.
47365539 08/07/2012
55.DTC / 320
for assistance.
47365539 08/07/2012
55.DTC / 321

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:

5. Connector pins corroded or dirty. When removing connectors inspect and clean pins. Clean female pins by
installing and removing.
Solution:
rence.

of fault.
47365539 08/07/2012
55.DTC / 322
B. NOT OK – Voltage is to low. Verify battery voltage. Check fuse F-001 and wiring to ECU. Return to Step
for assistance.
47365539 08/07/2012
55.DTC / 323
3293-Fuel Metering Unit: maximum positive deviation of rail

pressure exceeded
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
The fault is cause by a problem in the high pressure fuel supply.
1. Leakage in the high pressure system

2. Injection nozzle stuck in open position
3. Low efficiency of high pressure pump
4. Internal leakage of injector
5. Leaking pressure control valve
6. Low pressure at High pressure pump inlet due clogged filter
7. Leaking low pressure tubes
8. Electric pre supply pump defective or gear pump defective
Solution:
1. Check low pressure system for clogging (specially fuel filter).

Refer to the Operator’s Manual Fuel filter system - Check.
2. Check tubing between pre supply and gear pump.
3. Check feeding of pre supply pump (possibly low due to clogged tubes at tank outlet).
4. Check high pressure part for leakages (internal / external).
5. Check PCV for tightness in closed position (100% PWM).
6. Check High pressure pump for efficiency.
Refer to Injection pump - Timing check (10.218)
7. Check injectors for tightness.
47365539 08/07/2012
55.DTC / 324
3301-Fuel high pressure pump is at minimum delivery and the Rail

pressure is not reducing
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too high with a closed Metering
Unit (High Pressure Pump Regulator - solenoid valve). The rail pressure is monitored by various fault paths during
active pressure control by the metering unit. The fault path at hand detects an excessive negative rail pressure gov-
ernor deviation (too high rail pressure) at zero delivery of fuel volume flow through the metering unit. The monitoring
is only active if the high pressure governor is operating in closed loop control, the engine is not in overrun, the fuel
system temperature is above 29.96 °C (85.93 °F), the current injection quantity is above 0.0 g (0.00 oz) per cycle
and the monitoring has not been inhibited by other faults. If the negative rail pressure governor deviation is below the
engine speed dependent limit from a curve established by the ECU and the rail pressure governor set-point value of
the fuel volume flow is below threshold (parameter established by the ECU) over 8 seconds, this error will occur.
Cause:

Solution:
47365539 08/07/2012
55.DTC / 325
3305-Cannot maintain rail pressure above the minimum pressure

of 200 Bar
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that the Fuel Rail/System Pressure is too low. The rail pressure is
monitored by various fault paths during active pressure control by the metering unit. The fault path at hand detects if
the rail pressure has fallen below a minimum pressure threshold. The monitoring is only active if the high pressure
sure is below the engine speed dependent limit from a curve, established by the ECU, over 2.5 seconds this error will
occur. This error is the result of a leak in the high or low pressure side of the fuel rail system. On the high pressure
side check for worn or stuck open injector, worn high pressure pump or leaking pressure relief valve. On the low
pressure side check for low fuel pressure before or after the gear pump, clogged fuel filter or leakage.
47365539 08/07/2012
55.DTC / 326
3309-Maximum Fuel rail pressure exceeded

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:

Solution:
47365539 08/07/2012
55.DTC / 327
3334-Timeout of CAN Message TSC1 Speed

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
CAN Data Link communications from the ECU have been lost.
Cause:
CAN Data Link communications from the ECU have been lost. This fault code will be displayed with other CAN Data
Link fault messages. The engine may go into Limp Home Mode and engine speed will be set to 1500 RPM.
1. Connectors not mated fully, pins not fully seated in connector, bent pin or broken wire at rear of connector.
5. Faulty ECU
Solution:
last occurrence.
Fault code 3334 and 3339 may be active with other CAN Data Link faults code, such as 1051 and 1052. This is
an indication of a problem in the CAN Data Link circuit, continue with this procedure.
RCPH11TLB007FAL 1
machine service.
47365539 08/07/2012
55.DTC / 328
RCPH11TLB034GAL 2
47365539 08/07/2012
55.DTC / 329
CAN Low X-029 pin 3
CAN Low X-498 pin D


nector pin D)
47365539 08/07/2012
55.DTC / 330
RCPH11TLB074FAL 3
CAN Low X-029 pin 3
CAN Low X-498 pin D
47365539 08/07/2012
55.DTC / 331
RCPH11TLB072FAL 4
CAN Low X-029 pin 3
CAN Low X-498 pin D
A. All resistance measurements are less than 10 Ω. Temporarily replace the ECU and retest. Go to Step 1
to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 332
3339-Timeout of CAN Message TSC1 Torque

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
CAN Data Link communications from the ECU have been lost.
Cause:
CAN Data Link communications from the ECU have been lost. This fault code will be displayed with other CAN Data
Link fault messages. The engine may go into Limp Home Mode and engine speed will be set to 1500 RPM.
1. Problem in the CAN Bus wiring or CAB bus circuits.

2. Faulty Instrument Cluster or ECU (internal termination resistors).
3. Faulty Trax Control or Telematics unit.
Solution:
last occurrence.
Fault code 3334 and 3339 may be active with other CAN Data Link faults code, such as 1051 and 1052. This
is an indication of a problem in the CAN Data Link circuit, continue with 3334-Timeout of CAN Message TSC1
Speed (55.015).
RCPH11TLB007FAL 1
machine service.
B. NOT OK – CAN Data Link fault codes are present and ACTIVE. Go to troubleshooting procedure 3334-
Timeout of CAN Message TSC1 Speed (55.015) .
47365539 08/07/2012
55.DTC / 333
3361-ECM EEPROM - General Error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
1. Internal ECU error.
Solution:
rence.

(1) Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again go to Step 3.

3. Program the ECU (Engine Control Unit).
(1) Program the ECU using correct version of EST (Electronic Service Tool).
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again go to Step 4

(1) Remove and replace ECU (Engine Control Unit).
for assistance.
47365539 08/07/2012
55.DTC / 334
3362-Torque to Quantity Map - Not Plausible

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected an error. This failure can be the result of wrong programming / flashing
of the ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace
the ECU.
47365539 08/07/2012
55.DTC / 335
3363-Atmospheric Pressure Sensor - Processed via ADC, not

plausible
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
1. ECU internal error
Solution:
rence.

(1) Reset Engine Control Unit (ECU) by turning ignition switch OFF then back to the ON position.
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again go to Step 3.

3. Program the ECU (Engine Control Unit).
(1) Program the ECU using correct version of EST (Electronic Service Tool).
A. Return to Step 1 to confirm elimination of fault. If fault is recorded again go to Step 4

(1) Remove and replace ECU (Engine Control Unit).
for assistance.
47365539 08/07/2012
55.DTC / 336
3368-Torque limitation due to performance limiter, may be triggered

by inducament
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) has detected an active power reduction due to the OBD performance limiter. This
error is for informational purposes and is initiated by a power reduction due to the OBD performance limiter because
of inhibited injection being active causing a torque limitation greater than 25 % of the desired torque for longer than
60 seconds and is reset once the torque limitation due to the OBD performance limiter because of inhibited injection
is less than 25 % of the desired torque over 10 seconds. Though no action is necessary due to this error, if the power
reduction occurred due to an actual defect, the error triggering the torque limitation should also be in fault memory.
Follow the troubleshooting procedure for that error.
47365539 08/07/2012
55.DTC / 337
3369-Torque limitation due to smoke limitation has been active

for 120 seconds
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) has detected an active power reduction due to smoke limitation. This error is for
informational purposes and is initiated by a power reduction due to smoke limitation being active causing a torque
limitation greater than 25 % of the desired torque for longer than 60 seconds and is reset once the torque limitation
due to smoke limitation is less than 25 % of the desired torque over 10 seconds. Though no action is necessary due
to this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation should
also be in fault memory. Follow the troubleshooting procedure for that error.
47365539 08/07/2012
55.DTC / 338
3370-Torque limitation due to engine protection

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) has detected an active power reduction due to engine mechanics protection. This error
is for informational purposes and is initiated by a power reduction due to engine mechanics protection being active
causing a torque limitation greater than 25 % of the desired torque for longer than 60 seconds and is reset once the
torque limitation due to engine mechanics protection is less than 25 % of the desired torque over 10 seconds. Though
no action is necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering
the torque limitation should also be in fault memory. Follow the troubleshooting procedure for that error.
47365539 08/07/2012
55.DTC / 339
3371-Torque limitation due to Fuel quantity Limitation

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) has detected an active power reduction due to limiting fuel quantity. This error is for
informational purposes and is initiated by a power reduction due to limiting fuel quantity being active causing a torque
limitation greater than 25 % of the desired torque for longer than 60 seconds and is reset once the torque limitation
due to limiting fuel quantity is less than 25 % of the desired torque over 10 seconds. Though no action is necessary
due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque limitation
should also be in fault memory. Follow the troubleshooting procedure for that error.
47365539 08/07/2012
55.DTC / 340
3374-Unit injector NEMA codes are invalid

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that the EEPROM Adjustment Value Checksum is invalid. For every
individual unit injector an injection quantity adjustment (NIMA) can be programmed in the EEPROM for the entire
operating range. The monitoring function at hand checks if the EEPROM block holding these quantity adjustment
codes can be read successfully and if the cylinder individual checksums of the codes are correct. This monitoring
function is carried out at every ECU initialization (reset). Healing can, therefore, only occur by resetting the ECU.
This error will occur if the injector quantity adjustment code in the EEPROM of at least one cylinder contains an
invalid checksum and the injection quantities will not be corrected with the adjustment values. This error is cleared by
resetting (re-initializing) the ECU with a successful read of the injector quantity adjustment values form the EEPROM.
This error may be the result of an invalid NIMA code being programmed. Try to flash the ECU correctly with correct
NIMA codes and a proper dataset, if defect persists, replace the ECU.
47365539 08/07/2012
55.DTC / 341
3402-Rail pressure sensor: maximum rail pressure exceeded

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
sure exceeds the maximum pressure 1800 bar (26100 psi) over 1 second, this error will occur.
Cause:

Solution:
47365539 08/07/2012
55.DTC / 342
3405-ECU Power stages: Open load temperature error on the

Turbocharger PWM output power stage
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
ECU Power stages : Open load temperature error on the Turbocharger PWM output power stage.
Cause:
The ECU detects an open circuit in the turbocharger waste gate signal wire.
1. Faulty wiring
2. Faulty electric valve (WG)
3. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
(2) To check for fault codes: Start and operate machine.
A. Fault code 3405 is not recorded again. OK to return the machine to service.
B. Fault code 3405 is active and recorded again. Go to Step 2.

47365539 08/07/2012
55.DTC / 343
RCPH11TLB088FAL 2
Schematic legend
(1) Electronic Control Unit ECU (3) Electric Valve (WG)
Connector X-470
(2) B+ to Electric Valve (WG) (4) Exhaust Gas Absolute Pressure Sensor
Fuse F-038 7.5 A Connector X-470
ECU Wiring connections Circuit Name Wire ID Wiring connections

X-470
Switched Battery fro Fuse RD E058 X-470 pin 28
F-038
X-462 pin 4 Boost Pressure Actuator 1 GY F040 X-470 pin 27
X-462 pin 12 Gas Pressure Sensor PK F120 X-470 pin 21
Supply
X-462 pin 27 Gas Pressure Sensor BK/WH F270 X-470 pin 22
Ground
X-472 pin 43 Gas Pressure Signal YE F430 X-470 pin 23
(1) Inspect the ECU and the Electric Valve (WG). All connections should be secure, tight, free of corrosion,
(2) Inspect the harness from the ECU to the Electric Valve (WG). Verify that the harness is free of damage,
corrosion, abrasion and incorrect attachment.
A. The connectors are secure and the harness is free of damage. Go to Step 3.
3. Measure the voltage at the actuator connector
(2) Disconnect the Electric Valve (WG) connector.
47365539 08/07/2012
55.DTC / 344
(4) Measure the voltage from +Battery pin to chassis ground. The voltage should be approximately 12 V. Wiggle
A. The voltage is between 10 V and 14.8 V. Go to Step 4.
B. The voltage is less than 10 V. There is a problem in the battery supply to the valve. Check F-038. Repair
4. Measure the resistance through the valve
(2) Disconnect the Electric Valve connector.
(3) Measure the resistance through the motor windings. The resistance should be less than 100 Ω.
B. The resistance is greater than 100 Ω. There is an open circuit in the valve windings. Temporarily replace
the valve and retest. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance through the signal wire
(4) Measure the resistance from the Electric Valve signal wire to ECU connector X-462 pin 4. The resistance
should be less than 10 Ω. Wiggle the wire during measurement to reveal an intermittent condition.
B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. Repair or replace the wire
47365539 08/07/2012
55.DTC / 345
3406-ECU Power stages: Over temperature error on the

Turbocharger PWM output power stage
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
ECU Power stages : Over temperature error on the Turbocharger PWM output power stage
Cause:
The ECU detects an excess current draw on the turbocharger waste gate signal wire.
1. Faulty wiring
2. Faulty electric valve (WG)
3. Faulty ECU
Solution:
1. Verify that the fault code present on EST.
(1) Access the Electronic Service Tool fault code screen and monitor the fault codes.
(2) Verify that there are no fault codes pertaining to high battery voltage to the ECU or high fluid temperatures.
A. Fault code 3406 is active with other fault codes such as FC3051 or FC3518 or FC3007 and FC1002.
Troubleshoot these fault codes before troubleshooting FC3406.
B. Fault code 3406 is not recorded again. OK to return the machine to service.
C. Fault code 3406 is active and recorded again. Go to Step 2.

RCPH11TLB088FAL 1
47365539 08/07/2012
55.DTC / 346
Schematic legend
(1) Electronic Control Unit ECU (3) Electric Valve (WG)
Connector X-470
(2) B+ to Electric Valve (WG) (4) Exhaust Gas Absolute Pressure Sensor
Fuse F-038 7.5 A Connector X-470

X-470
Switched Battery fro Fuse RD E058 X-470 pin 28
F-038
X-462 pin 4 Boost Pressure Actuator 1 GY F040 X-470 pin 27
X-462 pin 12 Gas Pressure Sensor PK F120 X-470 pin 21
Supply
X-462 pin 27 Gas Pressure Sensor BK/WH F270 X-470 pin 22
Ground
X-472 pin 43 Gas Pressure Signal YE F430 X-470 pin 23
(1) Inspect the ECU and the Electric Valve (WG). All connections should be secure, tight, free of corrosion,
(2) Inspect the harness from the ECU to the Electric Valve (WG). Verify that the harness is free of damage,
3. Measure the voltage at the actuator connector
(2) Disconnect the Electric Valve (WG) connector.
(4) Measure the voltage from +Battery pin to chassis ground. The voltage should be approximately 12 V. Wiggle
B. The voltage is less than 10 V. There is a problem in the battery supply to the valve. Check F-038. Repair
C. The voltage is greater than 14.9 V. There is a problem in the battery supply to the valve. Troubleshoot the
High Voltage problem. Refer to FC3051 Engine control unit - High signal (55.015).
4. Measure the resistance through the valve to chassis ground
(3) Measure the resistance through the Electric Valve pin 1 to chassis ground. The resistance should be greater
than 20,000 Ω.
A. The resistance is greater than 20,000 Ω. Go to Step 5.
B. The resistance is less than 20,000 Ω. There is an internal short to chassis ground. Temporarily replace
the Electric Valve and retest. Return to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 347
(4) Measure the resistance from the ECU connector X-462 pin 4 to chassis ground. The resistance should be
greater than 20,000 Ω. Wiggle the wire during measurement to reveal an intermittent condition.
confirm elimination of the fault.
B. The resistance is less than 10 Ω. There is a short circuit in the signal wire to chassis ground. Repair or
replace the wire as required. Return to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 348
3408-Lambda sensor: Oxygen concentration implausibly high

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:
The expected O2 concentration is calculated using actual air flow and actual fuel injection. The calculated value is
outside of the normal operating range.
1. Leakage or block in the exhaust gas system

2. Blocked fuel lines to the injector
3. Problem in the injection system
4. Problem in the wiring to the Lambda sensor
NOTE: When testing the oxygen sensor a high impedance digital volt meter must be used. A normal analogue
multi-meter will draw too much current and either burn out the sensor or give false readings.
NOTE: When replacing the oxygen sensor, re-flash the control module to allow for the new sensor adjustments
to be learned.
5. Faulty Lambda sensor
6. Faulty ECU
Solution:
1. Verify the fault code is still present and in an active state.
A. If the fault is no longer active or present, check for an intermittent fault.
B. If the fault is still present and active, continue with step 2.

2. Check the turbo exhaust system
(1) Check the turbo and exhaust line for leaks and improper attachment.
A. The exhaust system is free of leaks and improper attachment. Go to Step 3.
B. The exhaust system has leaks and is need of repair. Repair the exhaust system as required. Return to
3. Check the fuel injection system
(1) Check the fuel lines to the injectors for leaks, blocks or improper attachment.
A. The fuel lines are free of leaks, blocks and improper attachment. Go to Step 4.
B. The fuel lines have leaks and are in need of repair. Repair the fuel lines as required. Return to Step 1 to
4. Place the key switch OFF. Disconnect the engine harness from the oxygen sensor at connector X–468. Inspect
all connectors, pins, and wiring harness for broken connectors, corrosion, bent pins or wire breaks.
47365539 08/07/2012
55.DTC / 349
RCPH11TLB083FAL 1
Schematic legend
(1) Lambda sensor B+ from ECU relay (3) Lambda sensor
X-464 terminal 87.
(2) Fuse F-038, 7.5 A (4) ECU
Wiring connections ECU Circuit Name Wire ID Wiring connections

Lambda sensor
X-461 pin 7 Lambda heating YE E070 X-468 pin 3
X-461 pin 63 Lambda voltage Nernst PK E630 X-468 pin 6
X-461 pin 64 Lambda current pump YE E640 X-468 pin 1
X-461 pin 85 Lambda virtual ground BK E850 X-468 pin 2
X-461 pin 86 Lambda current adjust YE E860 X-468 pin 5
Lambda sensor power RD E056 X-468 pin 4
A. If any damage is found, repair or replace connections, pins, or wiring. Return to Step 1 to confirm elimi-
nation of the fault.
B. If no damage is found, reconnect the wiring harness to the sensor. Continue with step 5.
5. Measure the voltage at the sensor
(1) Turn the key switch OFF
(2) Disconnect the Lambda sensor connector X-463.
(4) Measure the voltage between X-468 pin 4 and X-468 pin 2. The voltage should be approximately 12 V.
B. The voltage is less than 11 V. There is a problem in the battery supply to the sensor. Check fuse F-038.
Repair as required. Return to Step 1 to confirm elimination of the fault.
6. Measure the resistance through the wire harness
(2) Disconnect the ECU connector X-461 and the Lambda sensor connector X-468 .
47365539 08/07/2012
55.DTC / 350
(3) Measure the resistance between X-461 pin 7 and X-468 pin 3. The resistance should be less than 10 Ω.
B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair as required. Go to Step
1 to confirm elimination of the fault.
7. Measure the resistance of the harness to chassis ground
(2) Disconnect the ECU connector X-461 and the Lambda sensor connector X-468.
(3) Measure the resistance between X-461 pin 7 and chassis ground. The resistance should be greater than
20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance is greater than 20,000 Ω. Temporarily repalce the Lambda sensor and retest. Return to
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the wiring harness.
Repair as required. Go to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 351
3409-Oil pressure too low

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECU has detected a low oil pressure
Cause:
Engine speed is greater than 500 RPM and the oil pressure switch did not close. The oil pressure switch will close to
indicate to the ECU that the engine is running with the proper oil pressure.
1. Low engine oil level

2. Faulty engine lubrication system
3. Faulty electrical wiring, open circuit in the signal wire to the ECU
4. Faulty oil press switch
5. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
A. The fault is not recorded again. OK to return the machine to service.
B. Fault code 3409 is recorded again. Go to Step 2.

47365539 08/07/2012
55.DTC / 352
RCPH11TLB087FAL 2
Schematic legend
(1) Oil pressure switch (3) GND—011 Chassis Ground
(2) ECU
(1) Inspect the ECU and the Oil Pressure Switch connections. All connections should be secure, tight, free of
(2) Inspect the harness from the ECU to the Oil Pressure Switch. Verify that the harness is free of damage,
(2) Disconnect ECU connector X-462 and the Oil Pressure Switch connector X-470.
B. The resistance is greater than 10 Ω. There is an open circuit in the signal wire. repair as required. Go to
4. Measure the resistance through the oil pressure switch
(2) Disconnect the oil pressure switch connector.
(3) Start the engine. Set engine speed to 800 RPM.
(4) While the engine is running, measure the resistance through the switch to chassis ground. The chassis
ground connection should be clean and free of oil, paint and dirt. The resistance should be less than 10 Ω.
B. The resistance is greater than 10 Ω. There is a problem with the oil pressure switch. Temporarily replace
the oil pressure switch and retest. Return to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 353
3410-Permanent governor deviation for valve

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The positive limit of throttle valve governor deviation has been exceeded.
Cause:
Desired throttle valve position can not be reached due to sticking throttle valve. Possible throttle valve position sensor
mismatched
1. Faulty wiring
2. Throttle valve binding inside assembly
Solution:
RCPH11TLB089FAL 1
(1) ECU connector X-462

(2) EGR Valve connector X-470
(3) TVA Valve X-470
(1) Inspect the ECU and the TVA valve connections. All connections should be secure, tight, free of corrosion,
(2) Inspect the harness from the ECU to the TVA valve. Verify that the harness is free of damage, corrosion,
47365539 08/07/2012
55.DTC / 354
A. If the fault is no longer active or present, Ok to return the machine to service.
B. If the fault is still present and active, temporarily replace the throttle valve assemble and retest. return to
47365539 08/07/2012
55.DTC / 355

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The negative limit of throttle valve governor deviation has been exceeded.
Cause:
Desired throttle valve position can not be reached due to sticking throttle valve. Possible throttle valve position sensor
mismatched
1. Faulty wiring
2. Throttle valve binding inside assembly
Solution:
RCPH11TLB089FAL 1

(3) TVA Valve X-470
(1) Inspect the ECU and the TVA valve connections. All connections should be secure, tight, free of corrosion,
47365539 08/07/2012
55.DTC / 356
B. If the fault is still present and active, temporarily replace the throttle valve assemble and retest. return to
47365539 08/07/2012
55.DTC / 357
3414-3417-Short circuit in glow plug wiring

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Solution:
rence.
RCPH11TLB007FAL 1
A. A glow plug fault code is not recorded again. OK to return the machine to service.
B. A fault code pertaining to the glow plugs is active. Fault code 3414, 3415, 3416 or 3417 is recorded again.
Go to Step 2.
47365539 08/07/2012
55.DTC / 358
RCPH11TLB085FAL 2
Schematic legend
(1) B+ to GCU (3) GCU Glow Control Unit
Fuse F-035 60 A
(2) Glow plug connector X-470 (4) ECU
Wiring connections Circuit Name Wire ID Wiring connections GCU

X-461 pin 22 GCU Diagnostics YE E220 X-469 pin 3
X-461 pin 41 Glow plug ground BK E410 X-469 pin 5
X-461 pin 52 GCU Control ST YE E520 X-469 pin 8
X-470 pin 58 Glow Plug Cylinder 3 WH 1580 X-469 pin 1
Fuse F-035 60 A Battery supply RD 1040 X-469 pin 4
(1) Inspect the ECU , GCU and Glow Plug connections. All connections should be secure, tight, free of corrosion,
(2) Inspect the harness from the GCU to the Glow Plugs. Verify that the harness is free of damage, corrosion,
abrasion and incorrect attachment.
3. Measure the resistance through the Glow Plug wire.
(2) Disconnect GCU connector X-468. Measure the resistance between the Glow Plug wire on connector X-468
to chassis ground. The chassis ground connection must be clean and free of paint, oil and dirt. The resistance
should be approximately 1 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance is approximately 1 Ω. Temporarily replace the GCU and retest. Go to Step 1 to confirm
B. The resistance is less than 0.75 Ω. Go to Step 4.

4. Measure the resistance at the glow plug.
(2) Disconnect the glow plug connector.
47365539 08/07/2012
55.DTC / 359
GCU connector Wire ID A-011 connector Cylinder

X-469 pin 1 WH 1580 X-470 pin 58 Cyl. 3
X-469 pin 2 WH 1610 X-470 pin 61 Cyl. 1
X-469 pin 6 WH 1570 X-470 pin 57 Cyl. 4
X-469 pin 7 WH 1600 X-470 pin 60 Cyl. 2
(3) Measure the resistance between the Glow Plug and chassis ground. The chassis ground connection must
be clean and free of paint, oil and dirt. The resistance should be approximately 1 Ω.
A. The resistance is approximately 1 Ω. There is a problem in the wiring to the Glow Plug. Repair or replace
as required. Go to Step 1 to confirm elimination of the fault.
B. The resistance is less than 0.75 Ω. Temporarily replace the glow plug and retest. Go to Step 1 to confirm
47365539 08/07/2012
55.DTC / 360
3420-CAN Bus Received frames: DFC of Auxiliary Engine Shutdown

Switch Message
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECU received a shutdown message via the CAN Bus. This fault code does not indicate a failure but an external
shut down request.
47365539 08/07/2012
55.DTC / 361
3425-Turbocharger: Over boost deviation at P2 too high in pressure

charger regulator
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The boost pressure exceeds the maximum limit for a period greater than 5.0 s.
Cause:
The Engine Control Unit (ECU) is detecting inaccurate boost pressure.
1. Faulty wiring
2. Faulty Boost pressure sensor
3. Faulty EVGT actuator
4. Faulty ECU
Solution:
B. If fault code is no longer present, return unit to proper operation.

2. Check for other faults present. Verify no other faults are associated to the Boost pressure sensor.
A. If faults are present, correct those errors first. Then determine if this fault has been resolved.
B. If no other faults are present, continue with step 3.

3. Check for other faults present. Verify no other faults that are associated to the EVGT actuator.

4. Check ECU for proper operation. If no other errors are present and all wiring is correct, download the latest
version of the software.
A. If fault code is no longer present, return unit to proper operation.
B. If fault code is still active, replace the ECU.

47365539 08/07/2012
55.DTC / 362
3426-Low efficiency in DPF filter

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECU has detected a high differential pressure (low flow rate) across the particulate filter. Black smoke may be
visible at the exhaust. This is an indication of a cracked, clogged or improperly installed particulate filter. Repair or
replace the particulate filter as required.
47365539 08/07/2012
55.DTC / 363
3517-Atmospheric Temperature Sensor signal range check

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) generated an error from a fault associated with the Humidity/temperature sensor. This
error could result from a signal out of range or a signal that is erratic or intermittent. When the ECU determines that
the Humidity/temperature sensor value is not valid, it will substitute a value of 39.96 °C (103.93 °F).
Cause:
The Humidity/temperature sensor signal to the ECU is shorted to greater than 5.0 V.
1. Faulty electrical wiring or connections

2. Faulty ECU
Solution:
2. Verify proper operation of the Humidity/temperature sensor. Use electronic service tool (EST) to check the
voltage range. The proper voltage range is 2.0 V to 4.9 V.
A. If the voltage reading is high, greater than 4.9 V. Continue with step 3.
B. If the voltage reading is within the proper limits, fault may have been intermittent. Return machine to proper
operation.
3. Disconnect the Humidity/temperature sensor from the engine sensor harness. Use electronic service tool (EST)
to check the voltage range.
A. If there is 5.0 V. There is an open or short in the sensor ground circuit. Continue with step 5.
B. If there is greater than 5.0 V. Leave humidity/temperature sensor disconnected and continue with step 4.
4. Disconnect connector 1 at the ECU. Use electronic service tool (EST) to check the voltage range.
A. If there is 5.0 V. There is a short in the sensor supply circuit. Locate and repair the damaged wires or
replace the harness.
B. If there is greater than 5.0 V. The ECU has failed internally. Replace the ECU.
5. Use a multi-meter to check for voltage between humidity/temperature sensor connector, pin 4, to ground. There
should be no voltage.
A. If there is no voltage, continue with step6.
B. If there is voltage, the short is in this wire.Locate and repair shorted wire.
6. Use a multi-meter to check for voltage between humidity/temperature sensor connector, pin 1, to ground. There
should be no voltage.
A. If there is no voltage, the sensor has failed. Replace the sensor.
B. If there is voltage, the short is in this wire.Locate and repair shorted wire.
47365539 08/07/2012
55.DTC / 364
3518-Atmospheric Temperature Sensor signal range check

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) generated an error from a fault associated with the Humidity/temperature sensor. This
error could result from a signal out of range or a signal that is erratic or intermittent. When the ECU determines that
the Humidity/temperature sensor value is not valid, it will substitute a value of 39.96 °C (103.93 °F).
Cause:
The Humidity/temperature sensor signal to the ECU is shorted to ground.
1. Faulty electrical wiring or connections

2. Faulty ECU
Solution:
2. Verify proper operation of the Humidity/temperature sensor. Use electronic service tool (EST) to check the
voltage range. The proper voltage range is 2.0 V to 4.9 V.
A. If the voltage reading is low , less than 2.0 V. Continue with step 3.
B. If the voltage reading is within the proper limits, fault may have been intermittent. Return machine to proper
operation.
3. Disconnect the Humidity/temperature sensor from the engine sensor harness. Use a multi-meter to check be-
tween Humidity/temperature sensor connector, pin 1, and ground. There should not be continuity to ground.
A. If there is continuity. There is a short to ground in the sensor supply circuit. Continue with step 4.
B. If there is not continuity. Leave humidity/temperature sensor disconnected and continue with step 5.
4. Disconnect connector 1 at the ECU. Use multi-meter to check the harness side of pin 68 to ground. There
should not be continuity to ground.
A. If there is continuity. There is a short between connector 1, pin 68 and pin 1 of the Humidity/temperature
sensor connector. Locate and repair the damaged wires or replace the harness.
B. If there is no continuity. The ECU has failed internally. Replace the ECU.
5. Disconnect connector 1 . Use a multi-meter to check for continuity between connector 1, pin 26, to ground.
A. If there is continuity, the short is in this wire.Locate and repair shorted wire.
B. If there is no continuity, reconnect Humidity/temperature sensor connector and continue with step 6.
6. Use a multi-meter to check for continuity between the harness side of connector 1, pin 26, to ground.
A. If there is continuity, the sensor has failed. Replace the sensor.
B. If there is no continuity, the ECU has failed internally. Replace the ECU.
47365539 08/07/2012
55.DTC / 365
3616-Torque limitation due to turbo charger protection high altitude

operation related
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Engine Control Unit (ECU) has detected an active power reduction due to turbo charger protection. This error is
for informational purposes and is initiated by a power reduction due to turbo charger protection being active causing
a torque limitation greater than 25 % of the desired torque for longer than 60 seconds and is reset once the torque
limitation due to turbo charger protection is less than 25 % of the desired torque over 10 seconds. Though no action
is necessary due to this error, if the power reduction occurred due to an actual defect, the error triggering the torque
limitation should also be in fault memory. Follow the troubleshooting procedure for that error.
47365539 08/07/2012
55.DTC / 366
3648-EVGT Boost pressure monitoring for over boost

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The boost pressure exceeds 3.5 bar (50.8 psi) for over 1.0 s.
Cause:
The Engine Control Unit (ECU) is detecting inaccurate boost pressure.
1. Faulty wiring
2. Faulty Boost pressure sensor
3. Faulty EVGT actuator
4. Faulty ECU
Solution:

2. Check for other faults present. Verify no other faults are associated to the Boost pressure sensor.

3. Check for other faults present. Verify no other faults that are associated to the EVGT actuator.

4. Check ECU for proper operation. If no other errors are present and all wiring is correct, download the latest
version of the software.
A. If fault code is no longer present, return unit to proper operation.
B. If fault code is still active, replace the ECU.
47365539 08/07/2012
55.DTC / 367
3650-Battery voltage: SRC high for battery voltage sensor

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTICE: Check alternator output voltage, if above 18 V troubleshoot the charging system before proceeding.
Context:
The battery supply to the ECM is above the threshold. Verify the alternator output before continuing.
Cause:
2. Faulty ECM
Solution:
rence.
A. Fault code 3650 is recorded again. Go to Step 2.
B. Fault is not recorded again. OK for return to service.

(2) Inspect pins on Engine Control Unit (ECU) connector and on engine controller.
A. The voltage is correct. Temporarily replace the ECU and retest. Go to Step 1 to confirm elimination of the
fault.
B. The voltage is greater than 15 volts. Temporarily replace the alternator and retest. Go to Step 1 to confirm
47365539 08/07/2012
55.DTC / 368
3651-Battery voltage: SRC low for battery voltage sensor

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1. Low battery voltage.

4. Faulty ECU
Solution:
1. Verify that fault code 3651 is still active, refer to 0000 - Retrieving fault codes, Backhoes.
rence.

A. The voltage is approximately 14.5 V. Temporarily replace the ECU and retest. Go to Step 1 to confirm
B. The voltage is less than 10 V. Temporarily replace the alternator and retest. Go to Step 1 to confirm
47365539 08/07/2012
55.DTC / 369
3652-CAN Bus: Bus off of CAN node A

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:

4. Faulty ECU
Solution:
last occurrence.
an indication of an intermittent connection in the CAN circuit. Check all wires and connectors to verify they are
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 370
A. CAN Data Link fault codes are not recorded again and are no longer ACTIVE. OK to return the machine
service.
B. CAN Data Link fault codes are present and ACTIVE. Go to Step 2.
RCPH11TLB034GAL 2
47365539 08/07/2012
55.DTC / 371
(1) Switched battery to Diagnostic Port (6) CAN Bus to ECU

(2) Diagnostic Port X-002 (7) CAN Bus to Telematics (optional)
CAN Low X-498 pin D
(3) Diagnostic Port minus battery connec- (8) Switched battery to Telematics (optional)
tion Fuse F-001, 5 A
(4) CAN Bus to Trax Control (9) Drop harness
(5) CAN Bus to Instrument Cluster (10) Trunk harness
CAN Low X-029 pin 3
A. The CAN Data Link harness is not damaged and all connections are secure. Go to Step 3.
B. The harness is damaged or the connectors are loose or damaged. Repair or replace the harness as
required. Go to Step 1 to confirm elimination of fault.
B. The resistance is less than 50 Ω. Go to Step 6.


A. All resistance measurements are greater than 20,000 Ω. Verify the ECU is powered and operational. Verify
that all minus battery and chassis ground connections to the CAN Bus modules are clean and secure.
Return to Step 1.
B. The resistance is less than 20,000 Ω. There is a short circuit in the CAN Data Link. Temporarily replace
the CAN Data Link wires and retest. Repair or replace the harness as required. Go to Step 1 to confirm
47365539 08/07/2012
55.DTC / 372
nector pin D)
B. The resistance is less than 56 Ω there is a short circuit between the CAN High and CAN Low wires. Repair
or replace the harness as required. Go to test Step 1 to confirm elimination of the fault.
RCPH11TLB074FAL 3
CAN Low X-029 pin 3
CAN Low X-498 pin D
47365539 08/07/2012
55.DTC / 373
RCPH11TLB072FAL 4
CAN Low X-029 pin 3
CAN Low X-498 pin D
47365539 08/07/2012
55.DTC / 374
3655-Torque limitation, Engine protection: General report of the

event of torque limitations
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This is an information fault code only. The fault code is logged and indicates that engine torque has been limited.
Troubleshoot the fault codes that cause the reduction in power.
47365539 08/07/2012
55.DTC / 375
3656-Torque limitation, Engine protection: Torque limitation caused

by particulate filter
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This is an information fault code only. The fault code is logged and indicates that engine torque has been limited due
to a restriction in the particulate filter. Troubleshoot the fault codes that cause the reduction in power.
47365539 08/07/2012
55.DTC / 376
3663-EGR command saturation over higher threshold

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The positive limit of EGR valve governor deviation has been exceeded.
Cause:
Desired EGR valve position can not be reached due to sticking EGR valve. Possible EGR valve position sensor
mismatched
1. Faulty wiring
2. EGR valve binding inside assembly
Solution:
RCPH11TLB089FAL 1

(3) TVA Valve X-470
(1) Inspect the ECU and the EGR valve connections. All connections should be secure, tight, free of corrosion,
(2) Inspect the harness from the ECU to the EGR valve. Verify that the harness is free of damage, corrosion,
47365539 08/07/2012
55.DTC / 377
B. If the fault is still present and active, temporarily replace the EGR valve assemble and retest. return to
47365539 08/07/2012
55.DTC / 378
3664-EGR command saturation over lower threshold

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The negative limit of EGR valve governor deviation has been exceeded.
Cause:
mismatched
1. Faulty wiring
Solution:
RCPH11TLB089FAL 1

(3) TVA Valve X-470
47365539 08/07/2012
55.DTC / 379
47365539 08/07/2012
55.DTC / 380

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The positive limit of EGR valve governor deviation has been exceeded.
Cause:
mismatched
1. Faulty wiring
Solution:
RCPH11TLB089FAL 1

(3) TVA Valve X-470
47365539 08/07/2012
55.DTC / 381
47365539 08/07/2012
55.DTC / 382

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The negative limit of EGR valve governor deviation has been exceeded.
Cause:
mismatched
1. Faulty wiring
Solution:
RCPH11TLB089FAL 1

(3) TVA Valve X-470
47365539 08/07/2012
55.DTC / 383
47365539 08/07/2012
55.DTC / 384
3667-Open load error for power stage

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
ECU Power stages : Open load error on the EGR valve power stage.
Cause:
The ECU detects an open circuit in the EGR valve drive circuit. Electrical problem in the EGR valve actuator.
1. Faulty wiring
2. Faulty EGR valve
3. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 385
RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
X-462 pin 50 EGR actuator motor plus WH F500 X-470 pin 29
X-462 pin 35 EGR actuator motor minus GY F350 X-470 pin 30
X-462 pin 9 EGR Position Sensor Sup- PK F090 X-470 pin 33
ply
X-462 pin 39 EGR Position Sensor Sig- YE F390 X-470 pin 34
nal
X-472 pin 424 EGR Position Sensor BK/WH F240 X-470 pin 35
Ground
(1) Inspect the ECU and the EGR valve. All connections should be secure, tight, free of corrosion, abrasion and
damage.
3. Measure the resistance through the wiring harness
(2) Disconnect the EGR Valve connector. Disconnect the ECU connector.
(3) Measure the resistance between ECU connector X-462 pin 50 and EGR valve motor plus pin. The resistance
47365539 08/07/2012
55.DTC / 386
(4) Measure the resistance between ECU connector X-462 pin 35 and EGR valve motor minus pin. The resis-
tance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
(5) Measure the resistance between ECU connector X-462 pin 9 and EGR position sensor supply pin. The
resistance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
(6) Measure the resistance between ECU connector X-462 pin 39 and EGR position sensor signal pin. The
(7) Measure the resistance between ECU connector X-462 pin 24 and EGR position sensor ground pin. The
B. The resistance is greater than 10 Ω. There is an open circuit in the wire. Repair or replace the wire as
(2) Disconnect the EGR valve connector.
A. The resistance is less than 100 Ω. Temporarily repalce the ECU and retest. Return to Step 1 to confirm
47365539 08/07/2012
55.DTC / 387
3668-Over temperature error for H-bridge

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
ECU Power stages : Over temperature error on the Turbocharger PWM output power stage
Cause:
The ECU detects an excess current draw on the turbocharger waste gate signal wire.
1. Faulty wiring
2. Faulty EGR valve
3. Faulty ECU
Solution:

RCPH11TLB089FAL 1

(3) TVA Valve X-470
47365539 08/07/2012
55.DTC / 388

X-470
ply
nal
Ground
damage.
3. Measure the resistance through the wiring harness.
(3) Measure the resistance between ECU connector X-462 pin 50 and EGR valve motor plus pin. The resistance
4. Measure the resistance through the wiring harness to chassis ground.
(3) Measure the resistance between ECU connector X-462 pin 50 and chassis ground. The resistance should
be greater than 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the wire
5. Measure the resistance through the valve to chassis ground.
than 20,000 Ω.
47365539 08/07/2012
55.DTC / 389
47365539 08/07/2012
55.DTC / 390
3669-Short circuit to battery on Out1 error for H-bridge

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Short circuit to battery on Out1 error for H-bridge. The ECU had detected a short circuit to an external power source.
Cause:
The EGR valve drive circuit is shorted to positive battery.
1. Wiring shorted to positive battery source.

2. Faulty ECU
Solution:
1. Check for active fault codes.
(1) Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
rence.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 391
RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
ply
nal
Ground
damage.
3. Measure the voltage through the wiring harness
(2) Disconnect the EGR valve connector. Disconnect the ECU connector.
(4) Measure the voltage from ECU connector X-462 pin 50 to chassis ground. The voltage should be less than
0.5 V. Wiggle the harness during measurement to reveal an intermittent condition.
47365539 08/07/2012
55.DTC / 392
B. The voltage is greater than 0.5 V. There is a short circuit to another voltage source. Repair or replace the
47365539 08/07/2012
55.DTC / 393

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:
The EGR valve drive circuit is shorted to positive battery.

2. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 394
RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
ply
nal
Ground
damage.
47365539 08/07/2012
55.DTC / 395
47365539 08/07/2012
55.DTC / 396
3671-Short circuit to ground on Out1 error for H-bridge

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECU had detected a short circuit to minus battery or chassis ground on Out1 error for H-bridge.
Cause:
The EGR valve drive circuit or wiring is shorted to minus battery or chassis ground.
1. Wiring shorted to minus battery or chassis ground.

2. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 397
RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
ply
nal
Ground
damage.
3. Measure the resistance of the harness to chassis ground.
(3) Measure the resistance from ECU connector X-462 pin 50 to chassis ground. The resistance should be
greater than 20,000 Ω . Wiggle the harness during measurement to reveal an intermittent condition.
47365539 08/07/2012
55.DTC / 398
Repair or replace the harness as required. Return to Step 1 to confirm elimination of the fault.
4. Measure the resistance of the valve to chassis ground.
(3) Measure the resistance from the EGR valve, motor plus pin to chassis ground. The resistance should be
greater than 20,000 Ω.
RCPH11TLB091FAL 3
(1) ECU (4) EGR Valve

(2) Connector X-470 (5) Chassis ground
(3) Digital Voltmeter set to measure resis-
tance
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the solenoid valve.
Temporarily replace the valve and retest. Return to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 399

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:

2. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 400
RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
ply
nal
Ground
damage.
47365539 08/07/2012
55.DTC / 401
RCPH11TLB091FAL 3

tance
47365539 08/07/2012
55.DTC / 402
3673-Short circuit over load error for H-bridge

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECU had detected a short circuit in the ERG valve drive circuit.
Cause:
The ECU had detected a short circuit in the ERG valve drive circuit.
1. Wiring shorted.
2. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 403
RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
ply
nal
Ground
damage.
(3) Measure the resistance between ECU connector X-462 pin 50 and ECU connector X-462 pin 35. The re-
sistance should be greater than 20,000 Ω . Wiggle the harness during measurement to reveal an intermittent
condition.
47365539 08/07/2012
55.DTC / 404
B. The resistance is less than 20,000 Ω. There is a short circuit in the wiring harness. Repair or replace the
RCPH11TLB091FAL 3

tance
47365539 08/07/2012
55.DTC / 405
3674-Under voltage error for H-bridge

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Under voltage error for H-bridge.
Cause:
The ECU had detected a high fluctuations in the system voltage.
1. Bad battery or battery connection

3. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
B. Fault code 3674 is recorded with other fault codes such as FC1014 or FC3051. Refer to Battery - Inspect
and clean (55.302), Battery - Test (55.302) and Alternator - Testing (55.301)
47365539 08/07/2012
55.DTC / 406
2. Inspect the battery cable connections.
(1) Verify that the battery terminals and battery cables are free of corrosion, abrasion and incorrect attachment.
(2) Verify that the battery chassis ground connection is clean and fastened securely to the frame. The chassis
connection point should be free of paint, rust, dirt and debris.
A. The cables and battery connections are secure and free of corrosion, abrasion and incorrect attachment.
Go to Step 3.
B. The battery connections or battery cables are in need of repair. Repair as required. Return to Step 1 to
(1) Inspect the ECU. All connections should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Battery to the ECU. Verify that the harness is free of damage, corrosion, abra-
sion and incorrect attachment.
A. The connectors are secure and the harness is free of damage. Temporarily replace the ECU and retest.
Return to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 407
3675 -DFC for long time valve drift at closed position

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Exhaust Gas Regeneration (EGR) Valve actuator is monitored for long time drift by comparing first and last learned
voltage compensation. Check the EGR valve is not blocked or clogged. Remove the EGR valve and inspect for any
carbon build up. If there is carbon build up, clean the EGR valve. Once the EGR valve has been cleaned, reinstall
EGR valve and clear any codes. Restart the machine and operate. If the fault code reoccurs, replace the EGR valve.
47365539 08/07/2012
55.DTC / 408
3676-DFC for valve position sensor voltage SRC high

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
DFC for valve position sensor voltage SRC high
Cause:
The ECU had detected an open circuit in the EGR position sensor.
1. Faulty wiring
2. Faulty EGR valve
3. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 409
RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
ply
nal
Ground
damage.
3. Measure the resistance through the harness.
(2) Disconnect the ECU connector, X-462 and the EGR valve connector.
(3) Fabricate a jumper wire 20 cm (8 in).
47365539 08/07/2012
55.DTC / 410
(4) Use the jumper wire to connect ECU connector X-462 pin 9 to X-462 pin 39.
(5) Measure the resistance between ERG valve sensor supply and EGR valve sensor signal. The resistance
RCPH11TLB092FAL 3

(2) Connector X-470 (5) Jumper wire, 20 cm (8 in)
tance
(6) Use the jumper wire to connect ECU connector X-462 pin 24 to X-462 pin 39.
(7) Measure the resistance between ERG valve sensor ground and EGR valve sensor signal. The resistance
B. The resistance is greater than 10 Ω. There is an open circuit in the wiring. Repair or replace the harness
4. Measure for stray voltage to chassis ground.
(2) Disconnect the ECU connector, X-462 . Disconnect the EGR valve connector.
A. The voltage is less than 0.5 V. Go to Step 4.
B. The voltage is greater than 0.5 V. There is a short circuit in the wiring to another voltage source. Repair
or replace the harness as required. Return to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 411
5. Measure the resistance through the position sensor
(2) Disconnect the EGR valve.
(3) Measure the resistance between the EGR position sensor supply pin and the EGR position sensor signal
pin. The resistance should be less than 10,000 Ω. If possible, move the valve while monitoring the resistance.
The resistance should change at an even rate.
RCPH11TLB093FAL 4
(1) ECU (3) Digital Voltmeter set to measure resis-

tance
(2) Connector X-470 (4) EGR Valve
(4) Measure the resistance between the EGR position sensor supply ground and the EGR position sensor signal
pin. The resistance should be less than 10,000 Ω. If possible, move the valve while monitoring the resistance.
The resistance should change at an even rate.
A. The resistance is less than 10,000 Ω and the resistance changes at an even rate when the valve is moved.
Temporarily replace the ECU and retest. Return to Step 1 to confirm elimination of the fault.
B. The resistance is greater than 10,000 Ω or the resistance did not change at a smooth rate. There is an
open circuit in the valve position sensor. Temporarily replace the EGR valve and retest. Return to Step 1
to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 412
3677-DFC for valve position sensor voltage SRC low

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
DFC for valve position sensor voltage SRC low
Cause:
The ECU had detected a short circuit to ground in the EGR position sensor.
1. Faulty wiring
2. Faulty EGR valve
3. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 413
RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
ply
nal
Ground
damage.
(2) Disconnect the ECU connector, X-462 and the EGR valve connector.
(3) Measure the resistance from ECU connector X-462 pin 9 to chassis ground. The resistance should be greater
than 20,000 Ω . Wiggle the harness during measurement to reveal an intermittent condition.
47365539 08/07/2012
55.DTC / 414
B. The resistance is less than 20,000 Ω. There is an short circuit to chassis ground in the wiring. Repair or
replace the harness as required. Return to Step 1 to confirm elimination of fault.
4. Measure resistance of the position sensor to chassis ground.
(2) Measure the resistance from the EGR position sensor supply pin to chassis ground. The resistance should
be greater than 20,000 Ω.
RCPH11TLB094FAL 3

tance
(3) Measure the resistance from the EGR position sensor signal pin to chassis ground. The resistance should
(4) Measure the resistance from the EGR position sensor ground pin to chassis ground. The resistance should
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the position sensor.
Temporarily replace the EGR valve and retest. Return to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 415
3680-Injection cut off: Injection cut off demand (ICO) for shut off
coordinator
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This fault is triggered when the Engine Control Unit (ECU) has an internal failure that concerns the reliability of the
accelerator pedal signal, fuel injection parameters or engine speed failures are detected. Another fault will be active
when this fault occurs. Refer to other fault present. Correct that fault, and erase fault codes.
47365539 08/07/2012
55.DTC / 416
3688-Water sensor in the fuel filter: WIF sensor check is failed

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECU has detected excess water in the fuel system. This message is sent to the Instrument Cluster via the CAN
Bus. The Instrument Cluster will illuminate the amber warning light while the is active fault.
Cause:
This fault code is displayed to warn the operator that the ECU has detected excess water in the fuel system.
Solution:
1. Check for active fault codes
(1) Drain the fuel filter of excess water.
(2) Use the Electronic Service Tool to clear all fault codes. Refer to 0000 - Retrieving fault codes, Backhoes.
rence.
A. Fault code 3688 is no longer active. OK to return the machine to service.
B. Fault code 3688 is active. Go to Step 2.

(1) Inspect the ECU and the Water In Fuel Sensor connections. All connections should be secure, tight, free of
(2) Inspect the harness from the ECU to the WIF Sensor. Verify that the harness is free of damage, corrosion,
RCPH11TLB086FAL 1
47365539 08/07/2012
55.DTC / 417
3. Disconnect the WIF sensor
(2) Disconnect the WIF sensor.
A. The fault code is not active while the sensor is disconnect and the fault code is active while the sensor is
connected. Temporarily replace the WIF sensor and retest. Go to Step 1 to confirm elimination of the fault.
B. The fault code is active while the sensor is disconnected. Go to Step 4.

4. Disconnect the WIF signal wire at the ECU
(2) Disconnect the WIF sensor signal wire, X-461 pin 30.
A. The fault code is not active while the signal wire is disconnect and the fault code is active when the signal
wire is connected. The WIF sensor signal wire is shorted to chassis ground or minus battery. Temporarily
replace the signal wire and retest. Go to Step 1 to confirm elimination of the fault.
B. The fault code is active while the WIF sensor signal wire is disconnected. Temporarily repalce the ECU
47365539 08/07/2012
55.DTC / 418
3689-Faulty diagnostic data transmission or protocol error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECU has detected a faulty diagnostic data transmission or protocol error from the Glow Plug Control Unit.
Cause:
The ECU has detected a faulty diagnostic data transmission or protocol error from the Glow Plug Control Unit.
1. Battery voltage to the GCU

2. Wiring problem in the glow plug system
3. Faulty GCU
4. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 419
RCPH11TLB085FAL 2
Schematic legend
Fuse F-035 60 A

(1) Inspect the ECU, GCU and Glow Plug connections. All connections should be secure, tight, free of corrosion,
3. Measure the voltage to the GCU.
(2) Disconnect the GCU connector X-469.
(4) Measure the voltage from X-469 pin 4 to chassis ground. The voltage should be approximately 12 V. Wiggle
A. The voltage is between 11 - 14.8 V. Go to Step 3.
B. The voltage is less than 11 V. There is a problem in the battery supply to the GCU. Check fuse F-035. Verify
battery connections from the starter motor. Repair as required. Return to Step 1 to confirm elimination of
the fault.
47365539 08/07/2012
55.DTC / 420
4. Measure the resistance of the glow plug ground wire and signal wires.
(2) Disconnect the glow plug connector, X-469. Disconnect ECU connector X-461.
(3) Measure the resistance between the X-469 pin 5 and ECU connector X-461 pin 41. The resistance should
be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Pay particular
attention to the splice area, SP-203 .
A. The resistance is less than 10 Ω Temporarily replace the GCU and retest. Return to Step 1 to confirm
47365539 08/07/2012
55.DTC / 421
3690-DFC for glow module error in GCU-T

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECU has detected an error in the GCU.
Cause:
Failure detected in the low voltage glow module (GCU-T)
1. Battery voltage to the GCU

2. Wiring problem in the glow plug system
3. Faulty GCU
4. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 422
RCPH11TLB085FAL 2
Schematic legend
Fuse F-035 60 A

the fault.
47365539 08/07/2012
55.DTC / 423
be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Pay particular
A. The resistance is less than 10 Ω Temporarily replace the GCU and retest. Return to Step 1 to confirm
47365539 08/07/2012
55.DTC / 424
3691-No load error for low voltage system

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Solution:
rence.
RCPH11TLB007FAL 1
B. A fault code pertaining to the glow plugs is active. Go to Step 2.

RCPH11TLB085FAL 2
47365539 08/07/2012
55.DTC / 425
Schematic legend
Fuse F-035 60 A

B. The resistance is greater than 1.5 Ω. Go to Step 4.


X-469 pin 1 WH 1580 X-470 pin 58 Cyl. 3
X-469 pin 2 WH 1610 X-470 pin 61 Cyl. 1
X-469 pin 6 WH 1570 X-470 pin 57 Cyl. 4
X-469 pin 7 WH 1600 X-470 pin 60 Cyl. 2
A. The resistance is approximately 1 Ω. There is an open circuit in the wiring to the Glow Plug. Repair or
replace as required. Go to Step 1 to confirm elimination of the fault.
B. The resistance is greater than 1.5 Ω. Temporarily replace the glow plug and retest. Go to Step 1 to confirm
47365539 08/07/2012
55.DTC / 426
3692-Over temperature error on ECU power stage for glow plug

low voltage system
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The GCU detects an over temperature error.
Cause:
Over temperature error on GCU power stage for glow plug low voltage system. Pre-glow and post-glow functions
may be disabled while this code is active. There may be starting issues such as black smoke and hard starts while
this code is active and the engine is cold.
1. High system voltage

2. High engine temperatures
3. Faulty wiring
4. Faulty GCU
5. Faulty ECU
Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes. Prior to clearing fault
codes write down all fault codes, number of occurrences, and engine hours at last occurrence.
RCPH11TLB007FAL 1
B. Fault code 3692 is recorded again. There are also fault codes for high battery voltage or high engine
temperatures. Troubleshoot these codes before troubleshooting FC3692.
47365539 08/07/2012
55.DTC / 427
C. Fault code 3692 is recorded and is active. Go to Step 2.

RCPH11TLB085FAL 2
Schematic legend
Fuse F-035 60 A

47365539 08/07/2012
55.DTC / 428
the fault.
(3) Measure the resistance between X-469 pin 5 and ECU connector X-461 pin 41. The resistance should be
less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Pay particular
less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
A. The resistance is less than 10 Ω Go to Step 5.
B. The resistance is less than 0.5 Ω There is a short circuit in the wiring or glow plug. Go to Step 6.
(2) Disconnect the glow plug connector at the glow plug.

X-469 pin 1 WH 1580 X-470 pin 58 Cyl. 3
X-469 pin 2 WH 1610 X-470 pin 61 Cyl. 1
X-469 pin 6 WH 1570 X-470 pin 57 Cyl. 4
X-469 pin 7 WH 1600 X-470 pin 60 Cyl. 2
A. The resistance is approximately 1 Ω. There is a short circuit in the wiring to the Glow Plug. Repair or
B. The resistance is less than 0.5 Ω There is a short circuit in the glow plug. Temporarily replace the glow
plug and retest. Go to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 429
3693-Short circuit to battery error for low voltage system

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Solution:
rence.
RCPH11TLB007FAL 1
B. A fault code pertaining to the glow plugs is active. Go to Step 2.

RCPH11TLB085FAL 2
47365539 08/07/2012
55.DTC / 430
Schematic legend
Fuse F-035 60 A

B. The resistance is greater than 1.5 Ω. Go to Step 4.


X-469 pin 1 WH 1580 X-470 pin 58 Cyl. 3
X-469 pin 2 WH 1610 X-470 pin 61 Cyl. 1
X-469 pin 6 WH 1570 X-470 pin 57 Cyl. 4
X-469 pin 7 WH 1600 X-470 pin 60 Cyl. 2
A. The resistance is approximately 1 Ω. There is an open circuit in the wiring to the Glow Plug. Repair or
B. The resistance is greater than 1.5 Ω. Temporarily replace the glow plug and retest. Go to Step 1 to confirm
47365539 08/07/2012
55.DTC / 431
3694-Short circuit to ground error for low voltage system

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The GCU detects an over temperature error.
Cause:
Over temperature error on GCU power stage for glow plug low voltage system. Pre-glow and post-glow functions
may be disabled while this code is active. There may be starting issues such as black smoke and hard starts while
this code is active and the engine is cold.

3. Faulty wiring
4. Faulty GCU
5. Faulty ECU
Solution:
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 432
RCPH11TLB085FAL 2
Schematic legend
Fuse F-035 60 A

the fault.
47365539 08/07/2012
55.DTC / 433
less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition. Pay particular
A. The resistance is less than 10 Ω Go to Step 5.
B. The resistance is less than 0.5 Ω There is a short circuit in the wiring or glow plug. Go to Step 6.
(2) Disconnect the glow plug connector at the glow plug.

X-469 pin 1 WH 1580 X-470 pin 58 Cyl. 3
X-469 pin 2 WH 1610 X-470 pin 61 Cyl. 1
X-469 pin 6 WH 1570 X-470 pin 57 Cyl. 4
X-469 pin 7 WH 1600 X-470 pin 60 Cyl. 2
A. The resistance is approximately 1 Ω. There is a short circuit in the wiring to the Glow Plug. Repair or
B. The resistance is less than 0.5 Ω There is a short circuit in the glow plug. Temporarily replace the glow
plug and retest. Go to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 434
3699-EEPROM: Error in EEPROM block EEPData1, SD correction

can not be calculated
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected an error during the last EEPROM write operation. The hardware encap-
sulation of the ECU checks each data block of the EEPROM and sets a status flag depending on if an error is found
or not found. This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Try to
flash the ECU correctly with the proper data set. If the error persists, replace the ECU.
47365539 08/07/2012
55.DTC / 435
3702-Injection control: Detection of failed engine start

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine did not start due a problem with engine speed or rail pressure. Troubleshoot the reasons why the engine
could not maintain a stating speed or insufficient fuel rail pressure.
47365539 08/07/2012
55.DTC / 436
3703-Injection control: check of minimum rail pressure

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
47365539 08/07/2012
55.DTC / 437
3704-3706- Injector adjustment programming: check of missing

injector adjustment value programming
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This fault has been generated due to the injector programming being incorrect. This failure can be the result of wrong
programming / flashing of the ECU or an internal defect. Using the Electronic Service Tool (EST), Easy-Engine soft-
ware, check the injector code matches the injector code used for that cylinder. Reprogram the engine control unit
(ECU) to the proper injector code. Try to flash the ECU correctly with the proper data set. If the error persists, replace
the ECU.
47365539 08/07/2012
55.DTC / 438
3707-Lambda sensor: Open circuit at the lambda sensor Nernst

cell pin
580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTE: When testing the oxygen sensor a high impedance digital volt meter must be used. A normal analogue multi-
meter will draw too much current and either burn out the sensor or give false readings.
NOTE: When replacing the oxygen sensor, re-flash the control module to allow for the new sensor adjustments to be
learned.
Context:
The engine control unit has detected an intermittent signal on the oxygen sensors voltage line at connector X-461 pin
63. This sensor is the primary measurement device for the fuel control to the ECU to know if the engine is too rich or
too lean.
Cause:
The oxygen sensor signal is not plausible.
1. Faulty electrical wiring or connection

2. Faulty oxygen sensor
3. Faulty control unit or software
Solution:

RCPH11TLB083FAL 1
Schematic legend
X-464 terminal 87.
(2) Fuse F-038, 7.5 A (4) ECU
47365539 08/07/2012
55.DTC / 439

Lambda sensor
A. If any damage is found, repair or replace connections, pins, or wiring.
3. Test the oxygen sensor for proper operation. Run the machine for approximately 10.0 min to allow the sensor
to warm up. Place the machine off. Use a back probe pin to connect the positive multi-meter lead to connector
X-468 pin 3 on the oxygen sensor. Place the negative lead to chassis ground. Have someone start the machine.
Rev the engine and monitor the voltage. The voltage range should vary between 0.1 - 0.9 V.
A. If the voltage is not in range the sensor has failed. Replace the sensor.
B. If the sensor is in range, continue with step 4.

4. Check for a grounded circuit. Place the key switch in the OFF position. Disconnect the engine harness from the
oxygen sensor at connector X-468 and at ECU connector X-461. Use a multi-meter to check for continuity from
the engine harness side of connector X-461 pin 63 to chassis ground. There should be no continuity.
A. If there is continuity, the damaged wiring is in the engine harness between connector X-468 pin 6 and
connector X-461 pin 63, wire E630 pink. Locate and repair the damaged wiring harness.
B. If there is no continuity, leave both connectors disconnected. Continue with step 5.

5. Check for a open circuit. Leave the key switch in the OFF position. Use a multi-meter to check for continuity from
the engine harness side of connector X-468 from pin 6 to connector X-461 pin 63. There should be continuity.
A. If there is no continuity, the damaged wiring is in the engine harness between connector X-468 pin 6 and
connector X-461 pin 63, wire E630 pink. Locate and repair the damaged wiring harness.
B. If there is continuity, re-flash ECU software. Check to verify the fault has cleared. If the fault has not
cleared. Replace the ECU.
47365539 08/07/2012
55.DTC / 440
3708-Lambda sensor: Open circuit at the lambda sensor pump

current pin
580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTE: Two people may be required to perform this test correctly.
learned.
Context:
The engine control unit has detected an intermittent signal on the oxygen current pump line at connector X-461 pin
64. This sensor is the primary measurement device for the fuel control to the ECU to know if the engine is too rich or
too lean.
Cause:

Solution:

RCPH11TLB083FAL 1
47365539 08/07/2012
55.DTC / 441
Schematic legend
X-464 terminal 87.
(2) Fuse F-038, 7.5 A (4) ECU

Lambda sensor

connector X-461 pin 64, wire E640 yellow. Locate and repair the damaged wiring harness.

47365539 08/07/2012
55.DTC / 442
3709-Lambda sensor: Open circuit at the lambda sensor virtual

ground pin
580N T4, 580SN T4, 580SN WT T4, 590SN T4
learned.
Context:
The engine control unit has detected an intermittent signal on the oxygen sensors ground line at connector X-461 pin
685. This sensor is the primary measurement device for the fuel control to the ECU to know if the engine is too rich
or too lean.
Cause:

Solution:

RCPH11TLB083FAL 1
47365539 08/07/2012
55.DTC / 443
Schematic legend
X-464 terminal 87.
(2) Fuse F-038, 7.5 A (4) ECU

Lambda sensor

connector X-461 pin 85, wire E850 black. Locate and repair the damaged wiring harness.

connector X-461 pin 85, wire E850 black. Locate and repair the damaged wiring harness.
47365539 08/07/2012
55.DTC / 444
3710-Lambda sensor: Fault to indicate dynamics of the sensor

signal too small
580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTE: When testing the lambda sensor a high impedance digital volt meter must be used. A normal analogue multi-
NOTE: When replacing the lambda sensor, re-flash the control module to allow for the new sensor adjustments to be
learned.
Context:
The engine control unit (ECU) has detected the measured oxygen concentration is incorrect. This sensor is the pri-
mary measurement device for the fuel control to the ECU to know if the engine is too rich or too lean.
Cause:

3. Faulty EGR valve
Solution:

RCPH11TLB083FAL 1
Schematic legend
X-464 terminal 87.
(2) Fuse F-038, 7.5 A (4) ECU
47365539 08/07/2012
55.DTC / 445

Lambda sensor

4. Check the wiring harness for any short or open circuits. Disconnect the engine harness from the oxygen sensor
at connector X-468 and the ECU at connector X-461. Using a multi-meter to test the wiring harness, refer to the
table below for test results.
Test Type From To Result

Continuity X-468 pin 3 X-461 pin 7 Continuity
Short Circuit X-468 pin 4 X-468 pin 3 No continuity
X-468 pin 1
X-468 pin 5
X-468 pin 2
X-468 pin 6
A. If any of the above tests fail. Locate and repair damaged wiring harness.
B. If the all the above test are correct, continue with step 5.
5. Check the injection system for any leaks or damages.
A. If the injectors or system has any leakages, repair or replace damage component.
B. If the injection system is in good condition, continue with step 6.

6. Check the EGR valve. Remove the EGR valve, and check if the valve is stuck open.
A. If the EGR valve is stuck open, clean or replace the EGR valve.
B. If the EGR valve is in good condition, place the EGR valve back onto the machine. Re-flash the ECU
software. Check to verify the fault has cleared. If the fault has not cleared. Replace the ECU.
47365539 08/07/2012
55.DTC / 446
3711-SCB error of the LSU Heater Power stage

580N T4, 580SN T4, 580SN WT T4, 590SN T4
learned.
Context:
The heater power stage of oxygen sensor is monitored for a short circuit to battery, as long as the heater is working.
Cause:
The oxygen sensor circuit is shorted to a high voltage source.

Solution:

2. Place the key switch OFF. Disconnect the engine harness from the oxygen sensor at connector X-468. Inspect
RCPH11TLB083FAL 1
Schematic legend
X-464 terminal 87.
(2) Fuse F-038, 7.5 A (4) ECU
47365539 08/07/2012
55.DTC / 447

Lambda sensor

4. Check wiring for shorted to power source. Place the key switch in the OFF position. Disconnect the engine
harness from the oxygen sensor at connector X-468 and at ECU connector X-461. Place the key switch ON.
Use a multi-meter to check for voltage from the engine harness side of connector X-468 pin 3 to chassis ground.
There should be no voltage.
A. If there is voltage, the damaged wiring is in the engine harness between connector X-468 pin 3 and con-
nector X-461 pin 7, wire E070 yellow. Locate and repair the damaged wiring harness.
B. If there is no voltage, leave both connectors disconnected. Continue with step 5.

5. Check to see if the wiring is shorted to the relay circuit. Place the key switch in the OFF position. Use a multi-
meter to measure the resistance from the engine harness side of connector X-468 from pin 3 to pin 4. The
resistance should be greater than 10.0 Ω.
A. If the resistance is below 10.0 Ω, the damaged wiring is in the engine harness between connector X-468
pin 3 and connector pin 4. Locate and repair the damaged wiring harness.
B. If the resistance is greater than 10.0 Ω, continue with step 6.

6. Check to see if the wiring is open. Place the key switch in the OFF position. Use a multi-meter to measure the
resistance from the engine harness side of connector X-468 from pin 3 to connector X-461 pin 7. The resistance
should be less than 10.0 Ω.
A. If the resistance is greater than 10.0 Ω, the damaged wiring is in the engine harness between connector
X-468 pin 3 and connector X-461 pin 7. Locate and repair the damaged wiring harness.
B. If the resistance is less than 10.0 Ω, continue with step 7.

7. Check software version is at the most current status. If the software version is not up to date, re-flash software
and recheck fault is present.
A. If the fault code is still active and present, replace the ECU.
B. If the fault code has cleared, return machine to proper service.

47365539 08/07/2012
55.DTC / 448
3712-Lambda sensor: SCG error of the LSU heater power stage

580N T4, 580SN T4, 580SN WT T4, 590SN T4
learned.
Context:
The heater power stage of the oxygen sensor is monitored against short circuit to ground, as long as the heater is
working.
Cause:
The oxygen sensor circuit is shorted to a ground source.

Solution:

2. Place the key switch OFF. Disconnect the engine harness from the oxygen sensor at connector X-468. Inspect
RCPH11TLB083FAL 1
Schematic legend
X-464 terminal 87.
(2) Fuse F-038, 7.5 A (4) ECU
47365539 08/07/2012
55.DTC / 449

Lambda sensor

4. Check wiring for shorted to ground source. Place the key switch in the OFF position. Disconnect the engine
harness from the oxygen sensor at connector X-468 and at ECU connector X-461. Place the key switch ON.
Use a multi-meter to measure the resistance from the engine harness side of connector X-468 pin 3 to chassis
ground. There should be approximately 1000 Ω.
A. If there is less than 1000 Ω, the damaged wiring is in the engine harness between connector X-468 pin 3
and connector X-461 pin 7, wire E070 yellow. Locate and repair the damaged wiring harness.
B. If there is approximately 1000 Ω, leave both connectors disconnected. Continue with step 5.
5. Check to see if the wiring is open. Place the key switch in the OFF position. Use a multi-meter to measure the
resistance from the engine harness side of connector X-468 from pin 3 to connector X-461 pin 7. The resistance
should be less than 10.0 Ω.
A. If the resistance is greater than 10.0 Ω, the damaged wiring is in the engine harness between connector
X-468 pin 3 and connector X-461 pin 7. Locate and repair the damaged wiring harness.
B. If the resistance is less than 10.0 Ω, continue with step 6.

6. Check software version is at the most current status. If the software version is not up to date, re-flash software
and recheck fault is present.
A. If the fault code is still active and present, replace the ECU.
B. If the fault code has cleared, return machine to proper service.

47365539 08/07/2012
55.DTC / 450
3713-Lambda sensor: Open Load error of the LSU Heater Power

stage
580N T4, 580SN T4, 580SN WT T4, 590SN T4
learned.
Context:
The heater power stage of the oxygen sensor is monitored against open load condition, as long as the heater is
working.
Cause:
The oxygen sensor circuit is has an open circuit condition.

Solution:

RCPH11TLB083FAL 1
Schematic legend
X-464 terminal 87.
(2) Fuse F-038, 7.5 A (4) ECU
47365539 08/07/2012
55.DTC / 451

Lambda sensor

4. Check for an open circuit. Place the key switch in the OFF position. Disconnect the engine harness from the
47365539 08/07/2012
55.DTC / 452
3714-Lambda sensor: Fault code to indicate SRC High error for

O2 calibration
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The analogic oxygen signal measured during calibration must be lower than 0.2 V.
Cause:
The analogic oxygen signal is greater than 0.2 V during calibration.

3. Problems with injection system or EGR
Solution:



X-468 pin 1
X-468 pin 5
X-468 pin 2
X-468 pin 6
47365539 08/07/2012
55.DTC / 453

47365539 08/07/2012
55.DTC / 454
3715-Lambda sensor: SRC Low error for O2 calibration

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The analogic oxygen signal measured during calibration must be lower than 0.2 V.
Cause:
The analogic oxygen signal is greater than 0.2 V during calibration.

3. Problems with injection system or EGR
Solution:



X-468 pin 1
X-468 pin 5
X-468 pin 2
X-468 pin 6
47365539 08/07/2012
55.DTC / 455

47365539 08/07/2012
55.DTC / 456
3720-Lambda sensor: Low battery voltage at the SPI chip

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The SPI chip reports a "very low battery voltage" defect (i.e. Voltage is less than 9.0 V).
Cause:
A low voltage source has been detected.

3. Faulty ECU
Solution:

B. If no damage is found, leave the connector disconnected. Continue with step 3.

3. Check the wiring harness. Disconnect the engine harness from the ECU at connector X-461. Place the ignition
switch OFF. Using a multi-meter to test the wiring harness, refer to the table below for test results.

Resistance X–461 pin 64 X–468 pin 1 Continuity
B. If the all the above test are correct, replace the oxygen sensor. Use EST to reset the ECU oxygen sensor
learning values. Recheck fault has cleared. If fault is still present, replace the ECU.
47365539 08/07/2012
55.DTC / 457
3721-Lambda sensor: Fault check to indicate SPI chip error of

lambda sensor
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected the initialization register value of the SPI chip is different from the value
written into the chip in the previous cycle. The SPI chip internal to the ECU is defective. Replace the ECU. .
47365539 08/07/2012
55.DTC / 458
3722-Lambda sensor: LSU sensor temperature Ri exceeds the

maximum limit
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Lambda Sensor (LSU) measures O2 concentration only correctly, when the measuring cell is in a certain tem-
perature range. The temperature is estimated by the inner resistance of the heater. If the estimated temperature is
higher than a threshold, a failure is reported.
Cause:
The calculated temperature (based on inner resistance) of the sensor exceeds 929.96 °C (1705.9 °F).
1. Disconnected oxygen sensor

Solution:



learning values.
47365539 08/07/2012
55.DTC / 459
3723-Lambda sensor: LSU sensor temperature Ri is below the

minimum limit
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The Lambda Sensor (LSU) measures O2 concentration only correctly, when the measuring cell is in a certain tem-
perature range. The temperature is estimated by the inner resistance of the heater. If the estimated temperature is
higher than a threshold, a failure is reported.
Cause:
The calculated temperature (based on inner resistance) of the sensor is below or equal to 719.96 °C (1327.9 °F).
1. Disconnected oxygen sensor

Solution:



learning values.
47365539 08/07/2012
55.DTC / 460
3724-Lambda sensor: Short to battery at IA, IP, UN, VG

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The SPI chip reports a "short circuit to battery" defect at any of the lines for Nernst Cell (UN), Virtual Ground (VG), or
Pump Cell (IA,IP)
Cause:
There is a short to high source in the oxygen sensor circuit.

2. Short to voltage on lines UN, VG, IA, IP
3. Open load in VG
Solution:


switch ON. Using a multi-meter to test the wiring harness, refer to the table below for test results.

Voltage X–468 pin 1 Ground No voltage
B. If the all the above tests are correct, continue with step 4.
4. Check for an open circuit. Place the ignition switch OFF. Use a multi-meter to check for continuity on the engine
harness from connector X-461 pin 85 to connector X-468 pin 2. There should be continuity.
A. If there is no continuity, there is an open circuit in the engine harness between connector X-461 pin 85 to
connector X-468 pin 2. Locate and repair damaged wiring.
B. If there is continuity, replace the oxygen sensor. Use EST to reset the ECU oxygen sensor learning values.
47365539 08/07/2012
55.DTC / 461
3725-Lambda sensor: Short to ground at IA, IP, UN, VG

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The SPI chip reports a "very low battery voltage" defect (i.e. Voltage is less than 9.0 V).
Cause:
A low voltage source has been detected.

3. Faulty ECU
Solution:



learning values. Recheck fault has cleared. If fault is still present, replace the ECU.
47365539 08/07/2012
55.DTC / 462
3727-Low oil viscosity

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This fault is the result of the oil viscosity breaking down below a first threshold. Once this fault is present, it remains
active until the oil is changed. Change the engine oil, and clear any fault codes present.
47365539 08/07/2012
55.DTC / 463
3728-Too low oil viscosity

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This fault is the result of the oil viscosity breaking down below a second threshold. Once this fault is present, it remains
active until the oil is changed. Change the engine oil, and clear any fault codes present.
47365539 08/07/2012
55.DTC / 464
3735-Fuel Metering Unit: over temperature of device driver of

metering unit
580N T4, 580SN T4, 580SN WT T4, 590SN T4

3. Faulty wiring
4. Faulty fuel metering unit
5. Faulty ECU
Solution:
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 465
RCPH11TLB095FAL 2
Schematic legend
(1) ECU (2) Fuel Metering Unit
(1) Inspect the ECU and Fuel Metering Unit connections. All connections should be secure, tight, free of corro-
sion, abrasion and damage.
(2) Inspect the harness from the ECU to the Fuel Metering Unit. Verify that the harness is free of damage,
3. Measure the resistance to chassis ground.
(2) Disconnect the ECU connector X-462. Disconnect the Fuel Metering Unit connector.
(3) Measure the resistance from X-462 pin 60 to chassis ground. The resistance should be greater 20,000 Ω.
(4) Measure the resistance from X-462 pin 15 to chassis ground. The resistance should be greater 20,000 Ω.
B. The resistance is less than 20,000 Ω. there is a short circuit to chassis ground in the wiring. Repair or
replace the wiring as required. Return to Step 1 to confirm elimination of the fault.
4. Measure the resistance of the fuel metering unit to chassis ground.
(2) Disconnect the Fuel Metering Unit connector.
(3) Measure the resistance from the fuel metering unit supply pin to chassis ground. The resistance should be
greater 20,000 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
47365539 08/07/2012
55.DTC / 466
RCPH11TLB096FAL 3
Schematic legend
(1) ECU (3) Digital Voltmeter set to measure resis-
tance
(2) Fuel Metering Unit (4) Chassis ground
B. The resistance is less than 20,000 Ω. there is a short circuit to chassis ground in the wiring. Repair or
replace the wiring as required. Return to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 467
3736-O2 concentration is outside the predefined window during

Heater coupling detection
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The heat up of the oxygen sensor is monitored by the ECU. If insufficient heater performance from the oxygen sensor
is detected for too long this fault code will occur. Replace the oxygen sensor.
47365539 08/07/2012
55.DTC / 468
3738-ECU Internal: Diagnostic fault check

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This failure can be the result of corrupted data or internal failure of the engine control unit (ECU). Try to flash the ECU
correctly with the proper data set. If the error persists, replace the ECU.
47365539 08/07/2012
55.DTC / 469
3739-Power stages, Injector: Loss of synchronization sending

bytes to the MM from CPU
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected a processing error during ECU start up. Try to flash the ECU correctly
with the proper data set. If the error persists, replace the ECU.
47365539 08/07/2012
55.DTC / 470
3740-Power stages, Injector: DFC to set a torque limitation once an

error is detected before MoCSOP's error reaction is set
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
If this fault is occurs, check for any other faults associated with the injectors. If other faults are present, correct those
faults first. Clear any faults codes that exist and recheck this fault has cleared. If no other codes are present, try to
flash the ECU correctly with the proper data set. If the error persists, replace the ECU.
47365539 08/07/2012
55.DTC / 471
3741-Power stages, Injector: Wrong set response time

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
If the engine control unit (ECU) times out during start up, this fault will occur. Try to flash the ECU correctly with the
proper data set. If the fault persists, replace the ECU.
47365539 08/07/2012
55.DTC / 472
3743-Power stages, Injector : Diagnostic fault check to report the

error in under voltage monitoring
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
If the engine control unit (ECU) detects under voltage in the ECU during start up, this fault will occur. Try to flash the
ECU correctly with the proper data set. If the fault persists, replace the ECU.
47365539 08/07/2012
55.DTC / 473
3773-EVGT Turbocharger Control Underboost Pressure failure

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Underboost is detected if the positive boost pressure deviation exceeds 0.4 bar (5.8 psi) for over 5.0 s while the
following conditions are met: Injection quantity is greater than 2.0 ml (0.1 US fl oz), and no boost pressure sensor
error.
Cause:
The ECU has detected a failure in boost pressure.
1. Faulty wiring
2. Faulty boost pressure sensor
3. Clogged air filter/intake system
4. Faulty turbocharger
Solution:

2. Check the air filter. Remove and inspect the air filter.
A. If the air filter is restricted, clean or replace the air filter.
B. If the air filter is free of restrictions, continue with step 3.

3. Check the intake system. Check for signs of restriction in the intake system.
A. If the intake is clogged, clean out intake system. If intake is damaged, replace the intake system.
B. If intake is free of restrictions, continue with step 4.

4. Check the boost pressure sensing circuit. Disconnect the engine sensor harness from the boost pressure sen-
sor. Place the ignition switch ON. Use a multi-meter to check for voltage from engine sensor harness side of
connector pin 4 to chassis ground. There should be no voltage.
A. If there is voltage, repair or replace wiring in the engine sensor harness.
B. If there is no voltage, leave connector disconnected. Continue with step 5.

5. Check the boost pressure sensing circuit. Place the ignition switch OFF. Disconnect the engine sensor harness
from the ECU. Use a multi-meter to check for continuity from engine sensor harness side of connector pin 4 to
connector pin 34. There should be continuity.
A. If there is no continuity, repair or replace wiring in the engine sensor harness.
B. If there is continuity, continue with step 6.

6. Check condition of turbocharger. Remove connectors from the turbocharger. Visually inspect the blades and
turbocharger housing for any damage.
A. If any damaged is found, replace the turbocharger.
B. If the turbocharger is in good condition, test complete

47365539 08/07/2012
55.DTC / 474
3786-Diesel particulate filter signal range check is high

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected the soot level in the DPF filter is exceeding the threshold limit, or the flow
resistance is high. If this fault occurs, black smoke should be visible at the exhaust pipe. Check that the DPF filter is
mounted properly and is not cracked. If the DPF filter is not mounted properly, refit the DPF filter correctly. If damaged
is determined, replace the DPF filter. This fault will clear at the end of the next regeneration cycle.
47365539 08/07/2012
55.DTC / 475
3787-Diesel particulate filter (DPF) : Signal range check flow

resistance of the particulate filter - very high
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected the soot level in the DPF filter is exceeding the threshold limit, or the flow
resistance is high. Check that the DPF filter is mounted properly and is not cracked. If the DPF filter is not mounted
properly, refit the DPF filter correctly. If damaged is determined, replace the DPF filter. This fault will clear at the end
of the next regeneration cycle.
47365539 08/07/2012
55.DTC / 476
3789-Regeneration duration exceeds maximum allowed duration

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected the regeneration cycle did not complete in time. This could be a cause
of exhaust restrictions, differential pressure sensor measuring wrong. Check the exhaust for any kind of restrictions.
Check rear differential pressure sensor hose is not clogged. Perform the manual regeneration procedure.
47365539 08/07/2012
55.DTC / 477
3790-Diesel particulate filter: Signal range check flow resistance of

the particulate filter - max
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The flow resistance, dependent on soot mass stored in the particulate filter, should not exceed a defined limit. If this
limit is exceeded, the diesel particulate filter is clogged, or a problem in the filter mounting should be assumed.
Cause:
The engine control unit (ECU) has detected the filtered flow is above maximum limit.
1. Diesel Particulate Filter (DPF) is clogged or not installed correctly.

2. Faulty wiring
3. Exhaust restriction
4. Faulty differential pressure sensor
Solution:
rence.
RCPH11TLB007FAL 1

2. Place the ignition switch ON. Run the diesel particulate filter regeneration cycle. Place the ignition switch OFF
for 1.0 min. Test drive the machine. Check if the fault code is still active or inactive.
47365539 08/07/2012
55.DTC / 478
A. If the fault code is no longer active. OK to return machine to service.
B. If the fault code is still active, continue with step 3.

3. Check the condition of the diesel particulate filter. Place the ignition switch OFF. Verify that the filter is installed
correctly.
A. If the filter is not installed correctly. Repair as required.
B. If the filter is installed correctly, continue with step 4.

4. Check the differential pressure sensor is installed correctly. Place the ignition switch OFF. Visually inspect the dif-
ferential pressure Sensor for physical damage, proper electrical connection and proper mechanical connection.
Ensure all tubes and/or hoses connected to the sensor are in good working condition and properly connected at
all ends. Visually inspect the entire exhaust system for bent, crushed or otherwise damaged tubes which may
cause an exhaust system restriction.
RCPH11TLB095AAL 2
(1) Differential Pressure Sensor (2) Connector X-475
A. Damage is found, repair or replace as necessary.
B. No damage is found, continue with step 5.

RCPH11TLB081FAL 3
Schematic legend
(1) ECU (3) Differential Pressure Sensor
(2) Inline Turbine Temperature Sensor
47365539 08/07/2012
55.DTC / 479
(1) Inspect the ECU and the Differential Pressure Sensor connections. All connections should be secure, tight,
(2) Inspect the harness from the ECU to the Differential Pressure Sensor. Verify that the harness is free of
6. Measure the sensor voltage
(2) Disconnect the Differential Pressure sensor from the engine harness. Reconnect the ECU connector X-461 .
(4) Measure the voltage between sensor connector X-475 pin 1 and X-475 pin 2. The voltage should be ap-
proximately 5 V.
A. The voltage is approximately 5 V. Go to Step 7.
B. The voltage is less than 5 V. There is a problem in the wiring to the sensor or the ECU sensor supply
voltage. Repair as required. Return to Step 1 to confirm elimination of fault.
7. Measure the resistance through the wire
(1) Disconnect the ECU connector and the Differential Pressure Sensor connector.
(2) Measure the resistance from X-461 pin 58 to X-475 pin 3. The resistance should be less than 10 V.
B. The resistance is greater than 10 Ω there is an open circuit in the signal wire. Repair as required. Return
8. Test the sensor circuit with a potentiometer
(2) Obtain a 5k Ω Potentiometer.
(3) Connect the CW lead to X-475 pin 1. Connect the CCW lead to X-475 pin 2. Connect the wiper to X-475
pin 3.
47365539 08/07/2012
55.DTC / 480
RCPH11TLB082FAL 4
Schematic legend
(1) ECU (3) 5k Ω potentiometer install in place of the
differential pressure sensor
Dealer Supplied
(4) Turn the key switch ON and monitor the fault code. Rotate the knob on the potentioment while monitoring
EST and the fault codes. The fault code should no longer be active.
A. Fault code 3790 is recorded again. Temporarily replace the ECU and retest and retest. Go to Step 1 to
B. Fault code 3790 is not recorded again. Temporarily replace the Differential Pressure Sensor and retest.
47365539 08/07/2012
55.DTC / 481
3794-Intake air pressure sensor: Plausibility check for air pressure

at the upstream of intake valve sensor
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
to the pressure sensing function of the device. This error could result from a signal out of range or a signal that is
either erratic or intermittent.
Cause:
The Boost Pressure sensor signal to the ECU is incorrect.

2. Faulty sensor.
Solution:

2. Inspect the harness between the boost pressure sensor and the ECU. Verify that the harness is free of damage,
corrosion, abrasion, or incorrect attachment.
A. If any damage is found in the wiring harness, repair or replace as required.
B. If no damage is found, continue with step 3

3. Check for a short to ground. Place the key switch OFF. Disconnect the engine harness from the boost pressure
sensor at connector X-470. Use a multi-meter to check for continuity from the engine harness side of connector
X-470 pin 18 to chassis ground. There should be no continuity.
A. If there is continuity, there is a short to ground condition in the engine harness between connector X-470
pin 18 and connector X-462 pin 40, wire F400 yellow. Locate and repair damaged wiring.
B. If there is no continuity, continue with step 4.

4. Check for an open circuit. Place the key switch ON. Use a multi-meter to check for voltage from the engine
harness connector X-470 pin 17 to chassis ground. There should be approximately 5.0 V.
A. If there is no voltage, there is an open circuit in the engine wiring harness between connector X-470 pin
18 and connector X-462 pin 40, wire F400 yellow. Locate and repair damaged wiring.
B. If there is 5.0 V, replace the boost pressure sensor.
47365539 08/07/2012
55.DTC / 482
3796-Diesel particulate filter pressure sensor hose line error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected the filtered differential pressure signal is below 1.0 kPa (0.1 psi). This
fault is a cause of a hose connection upstream from the diesel particulate filter not being attached, or is clogged.
Check mounting of the hose lines, and check the hose line is free of clogs.
47365539 08/07/2012
55.DTC / 483
3797-Diesel particulate filter pressure sensor: SRC high for

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Solution:
rence.
RCPH11TLB007FAL 1

47365539 08/07/2012
55.DTC / 484
RCPH11TLB081FAL 2
Schematic legend
RCPH11TLB095AAL 3
3. Create a short circuit at the sensor and test
(2) Disconnect the Differential Pressure Sensor.
(3) Fabricate a jumper wire 20 cm (8 in).
(4) Turn the key switch ON. Monitor the fault code screen on the EST.
(5) Short X-475 pin 2 to X-475 pin 3. The fault code should change from 3797 to a short circuit fault code 3798.
47365539 08/07/2012
55.DTC / 485
A. The fault code changed from an open circuit fault code FC3797 to a short circuit fault code FC3798. Tem-
porarily replace the Differential Pressure Sensor and retest. Go to Step 1 to confirm elimination of the fault
code.
B. The fault code did not change to a FC3798 short circuit fault code. Go to Step 4.
4. Create a short circuit at the ECU and test
(2) Use a wire removal tool to remove X-461 pin 58 from the ECU connector.
(3) Fabricate a jumper wire long enough to reach from chassis ground to X-461 pin 58. The chassis ground
connection should be clean and free of corrosion, paint, oil and dirt.
(4) Turn the key switch ON. Monitor the fault code screen on the EST.
(5) Short X-461 pin 58 to chassis ground. The fault code should change from FC3797 to a short circuit fault
code 3798.
A. The fault code changed from an open circuit fault code FC3797 to a short circuit fault code FC3798. There
is a problem in the wiring from the ECU to the sensor. Repair or replace the wire as needed. Go to Step
1 to confirm elimination of the fault code.
B. The fault code did not change to a FC3798 short circuit fault code. Temporarily replace the ECU and
47365539 08/07/2012
55.DTC / 486
3798-Diesel particulate filter pressure sensor: SRC low for

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Solution:
rence.
RCPH11TLB007FAL 1

47365539 08/07/2012
55.DTC / 487
RCPH11TLB081FAL 2
Schematic legend
RCPH11TLB095AAL 3
3. Create an open t circuit at the sensor and test
(3) Turn the key switch ON. Monitor the fault code screen on the EST. The fault code should change from 3798
to an open circuit fault code 3797.
(4) Short X-475 pin 2 to X-475 pin 3.
47365539 08/07/2012
55.DTC / 488
A. The fault code changed from a short circuit fault code FC3798 to an open circuit fault code FC3797. Tem-
porarily replace the Differential Pressure Sensor and retest. Go to Step 1 to confirm elimination of the fault
code.
B. The fault code did not change to a FC3797 open circuit fault code. Go to Step 4.
4. Create an open circuit at the ECU and test
(2) Use a wire removal tool to remove X-461 pin 58 from the ECU connector.
(3) Turn the key switch ON. Monitor the fault code screen on the EST. The fault code should change from FC3798
to an open circuit fault code 3797.
A. The fault code changed from a short circuit fault code FC3798 to an open circuit fault code FC3797. There
is a problem in the wiring from the ECU to the sensor. Repair or replace the wire as needed. Go to Step
1 to confirm elimination of the fault code.
B. The fault code did not change to FC3797 open circuit fault code. Temporarily replace the ECU and retest.
47365539 08/07/2012
55.DTC / 489
3799-Rail system: Rail pressure reduction by blank shots during

after run (BSA) aborted during post drive of ECU
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This code is not an actual failure. A rail pressure shock test was detected. Clear code and return machine to proper
use.
47365539 08/07/2012
55.DTC / 490
3800-Pressure relief valve: Quantity balance check if a successful

PRV opening is ensured
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This code is not a failure fault, the engine control unit (ECU) has detected the pressure shock was rejected because
fuel quantity is not in range. To determine mechanical wear out, the pressure relief valve can be forced open by
a pressure shock, when the metering valve of the high pressure fuel pump is set to maximum possible quantity.
Pressure shock is only possible in a defined engine speed range depending on rail pressure.
47365539 08/07/2012
55.DTC / 491
3801-Turbine upstream pressure sensor: SRC high for turbine

upstream pressure sensor
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected the inlet turbo temperature sensor sensed voltage is above 6.55 V.
Cause:
The inlet turbo temperature sensor signal is shorted to a high voltage source.
1. Faulty electrical wiring

2. Faulty sensor
3. Faulty control unit
Solution:
rence.
RCPH11TLB007FAL 1

47365539 08/07/2012
55.DTC / 492
RCPH11TLB082FAL 2
Schematic legend
(1) Inspect the ECU and the Inline Turbine Temperature Sensor connections. All connections should be secure,
(2) Inspect the harness from the ECU to the Inline Turbine Temperature Sensor. Verify that the harness is free
of damage, corrosion, abrasion and incorrect attachment.
3. Measure the resistance between the signal wires.
(2) Disconnect ECU connector X-461. Disconnect the Inline Turbine Temperature connector.
(3) Fabricate a jumper wire 20 cm (8 in) long. Use the jumper wire to short the Inline Turbine Temperature Sen-
sor connector X-470 pin 1 to pin 2. Wiggle the harness during measurement to reveal an intermittent condition.
B. The resistance is greater than 10 Ω there is an open circuit in the sensor wires. Repair or replace the
wires as required. Go to Step 1 to confirm elimination of fault.
4. Measure the resistance of the signal wire to battery.
(1) Disconnect ECU connector X-461. Disconnect the Inline Turbine Temperature connector.
(3) Measure the voltage between ECU connector X-461 pin 82 to chassis ground. The voltage should be less
than 0.2 V. Wiggle the harness during measurement to reveal an intermittent condition.
A. The voltage is less than 0.2 V, go to Step 5.
B. The voltage is greater than 0.2 V, the wire is shorted to another voltage source. Repair or replace the wire
47365539 08/07/2012
55.DTC / 493
5. Measure the resistance of the sensor.
(2) Disconnect the Inline Turbine Temperature connector.
(3) Measure the resistance of the Inline Turbine Temperature Sensor pin 1 to pin 2. The resistance should be
approximately 175 - 250 Ω.
A. The resistance is within the specified range. Temporarily replace the ECU and retest. Go to Step 1 to
confirm the elimination of the fault.
B. The resistance is not within the specified range. Temporarily replace the Inline Turbine Temperature and
retest. Go to Step 1 to confirm the elimination of the fault.
47365539 08/07/2012
55.DTC / 494
3802-Turbine upstream pressure sensor: SRC low for turbine

upstream pressure sensor
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit ( ECU ) has detected the inline turbine temperature sensor sensed voltage is less than 0.0 V.
Cause:
The inline turbine temperature sensor signal is shorted to a ground source.

2. Faulty sensor
Solution:
rence.
RCPH11TLB007FAL 1

47365539 08/07/2012
55.DTC / 495
RCPH11TLB082FAL 2
Schematic legend
(1) Inspect the ECU and the Inline Turbine Temperature Sensor connections. All connections should be secure,
(2) Inspect the harness from the ECU to the Inline Turbine Temperature Sensor. Verify that the harness is free
(2) Disconnect ECU connector X-461. Disconnect the Inline Turbine Temperature Sensor connector.
(3) Measure the resistance between ECU connector X-461 pin 82 to X-461 pin 81. The resistance should be
greater than 20,000 Ω Wiggle the harness during measurement to reveal an intermittent condition.
B. The resistance is less than 20,000 Ω there is a short circuit between the sensor wires. Repair or replace
the wires as required. Go to Step 1 to confirm elimination of fault.
4. Measure the resistance of the signal wire to chassis ground.
(2) Disconnect ECU connector X-461. Disconnect the Inline Turbine Temperature Sensor connector.
(3) Measure the resistance between ECU connector X-461 pin 82 to chassis ground. The resistance should be
B. The resistance is less than 20,000 Ω there is a short circuit between the sensor signal wire and chassis
ground. Repair or replace the signal wire as required. Go to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 496
(2) Disconnect the Inline Turbine Temperature Sensor connector.
(3) Measure the resistance of the Inline Turbine Temperature Sensor pin 1 to chassis ground. The resistance
should be greater than 20,000 Ω.
A. The resistance is greater than 20,000 Ω. Temporarily replace the ECU and retest. Go to Step 1 to confirm
the elimination of the fault.
B. The resistance is less than 20,000 Ω the sensor has a short circuit to chassis ground. Temporarily replace
the sensor and retest. Go to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 497
3803-ECU internal: Internal communication signals

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected an internal communication failure of several signals in the ECU due, for
example, to the supply voltage over the threshold. This failure can be the result of wrong programming / flashing of
the ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace
the ECU.
47365539 08/07/2012
55.DTC / 498
3808-Fuel Metering Unit: set point of metering unit in idle mode

not plausible
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This fault is a result of a leak on the high or low pressure side of the high side pressure pump. Check for worn or
stuck open injector, worn high pressure pump or leaking pressure control valve. Check for low fuel pressure before
or after the gear pump, clogged fuel filter or leakage, or faulty fuel pump.
47365539 08/07/2012
55.DTC / 499
3810-Rail pressure raw value is intermittent

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected an intermittent fault in rail pressure signal.
Cause:
There is a loose connection in the rail pressure circuit.
1. Faulty wiring or connection

2. Faulty sensor
Solution:
1. Disconnect the engine sensor harness from the rail pressure sensor. Inspect connector housing body/latch,
pins, and wiring harness for damage.
good sound electrical connection.
B. If no damaged is determine, continue with step 2.

2. Check the rail pressure sensor. Inspect connector housing body/latch, pins.
A. If damage is determined after careful inspection, replace the sensor. Re-flash the ECU.
B. If no damaged is found. Clear fault and return machine to proper operation.

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3811-ECU sensor supply monitor : ECU internal: Error sensor

supplies 1
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECM provides 3 independent 5V voltage supplies for the sensors. These sensor supply voltages are monitored
to ensure they remain within a given range.
Cause:
The sensor 5 volt supply is out of range.

3. Faulty wiring
4. Faulty ECU
Solution:
RCPH11TLB007FAL 1
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RCPH11TLB005HAL 2
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55.DTC / 502
Schematic legend
(1) ECU (5) EGR valve
(2) Differential pressure sensor (6) TVA Valve
(3) Rail pressure (7) Boost pressure/ Air temperature sensor
(4) Exhaust gas absolute pressure sensor
(1) Inspect the ECU and sensor connections, pay particular attention of the pressure and valve position sensors.
All connections should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the ECU to the sensors. Verify that the harness is free of damage, corrosion,
3. Measure the voltage of the 5 volt supply.
(4) Measure the voltage from the 5+ sensor supply to chassis ground. The voltage should be approximately 5
V. Wiggle the harness during measurement to reveal an intermittent condition.
RCPH11TLB097FAL 3
Schematic legend
(1) ECU (5) Chassis ground
(2) Sensor connector (6) +5 volt sensor supply
(3) Digital voltmeter set to measure voltage (7) Sensor signal to ECU
(4) Sensor, disconnected from the harness (8) Sensor ground
(5) Disconnect the other sensors one by one and measure the +5 volt sensor supply. The voltage should be
approximately 5 V. Wiggle the harness during measurement to reveal an intermittent condition.
A. The voltage is between 4.5 V and 5.5 V. Go to Step 4. The ECU +5 volt power supply is operating properly
at this time. Verify that the wiring and connectors are free of damage, corrosion and incorrect attachment.
B. The voltage is greater than 6 V. Go to Step 4.
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4. Measure the +5 volt supply at the ECU
(2) Use a wire removal tool to remove the suspect +5 volt sensor supply wire from the wiring harness.
(3) Fabricate a jumper wire 30 cm (12 in) and insert in into the open spot in the ECU connector.
(5) Measure the voltage from the +5 volt sensor supply jumper wire to chassis ground. The voltage should be
between 4.5 V and 5.5 V.
RCPH11TLB098FAL 4
Schematic legend
(1) ECU (5) Chassis ground
(2) Jumper wire for the +5 volt sensor supply (6) Sensor connector
(3) Digital voltmeter set to measure voltage (7) +5 volt sensor supply wire
(4) Sensor, disconnected from the harness
A. The voltage is between 4.5 V and 5.5 V. The +5 volt sensor supply in the wiring harness has a short
circuit to another voltage source. Repair or replace the harness as required. Return to Step 1 to confirm
B. The voltage is greater 5.5 V. There is a problem in the ECU +5 volt power supply. Temporarily replace the
ECU and retest. Return to Step 1 to confirm elimination of the fault.
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3812-Physical range check high for ECU temperature sensor

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECU detected an internal temperature above 130 °C (266 °F). This fault can be caused by a cooling system
problem, high environmental temperatures or due to heavy engine use. If the environmental temperature is not too
high and the machine has not been used heavily, let the engine cool down. Then check the cooling system has the
correct amount of coolant. Make sure the radiator is not clogged or is restricted of air flow.
High system voltages can contribute to this fault. Verify that the system voltage is correct and that there is not a
problem with the alternator charging system.

3. Faulty ECU
Solution:
C. Fault code 3812 is active and recorded again. Temporarily replace the ECU and retest. Return to Step 1
to confirm elimination of the fault. .
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3813-Physical range check low for ECU temperature sensor

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECU detected an internal temperature below the -40 °C (-40 °F). This fault can be caused by low environmental
temperatures. If the environmental temperature is not too low and the machine has not been used heavily, let the
engine warm up.
Low system voltages can contribute to this fault. Verify that the system voltage is correct and that there is not a
1. Low engine temperatures

2. Low system voltage
3. Faulty ECU
Solution:
A. Fault code 3813 is active with other fault codes such as FC3052 or FC3008. Troubleshoot these fault
codes before troubleshooting FC3813.
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3814-ECU temperature sensor: SPI error ECU temperature sensor

(LM71)
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECU detected an internal temperature above 130 °C (266 °F). This fault can be caused by a cooling system
correct amount of coolant. Make sure the radiator is not clogged or is restricted of air flow.
High system voltages can contribute to this fault. Verify that the system voltage is correct and that there is not a

3. Faulty ECU
Solution:
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3815-Low efficiency in DPF filter

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected an error associated with the diesel particulate filter (DPF). If this fault
occurs, black smoke should be visible at the exhaust pipe. Check that the DPF is mounted properly and is not cracked.
If the filter is not mounted properly, refit the filter correctly. If damaged is determined, replace the filter.
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55.DTC / 508
3818-Open load error for power stage

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
ECU Power stages : Open load error on the TVA valve power stage.
Cause:
The ECU detects an open circuit in the TVA valve drive circuit. Electrical problem in the TVA valve actuator.
1. Faulty wiring
2. Faulty TVA valve
3. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
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RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
X-462 pin 49 TVA actuator motor plus WH F490 X-470 pin 37
X-462 pin 34 TVA actuator motor minus GY F340 X-470 pin 38
X-462 pin 8 TVA Position Sensor Sup- PK F080 X-470 pin 41
ply
X-462 pin 53 TVA Position Sensor Sig- YE F530 X-470 pin 42
nal
X-472 pin 37 TVA Position Sensor BK/WH F370 X-470 pin 43
Ground
(1) Inspect the ECU and the TVA valve. All connections should be secure, tight, free of corrosion, abrasion and
damage.
3. Measure the resistance through the wiring harness
(2) Disconnect the TVA Valve connector. Disconnect the ECU connector.
(3) Measure the resistance between ECU connector X-462 pin 49 and TVA valve motor plus pin. The resistance
47365539 08/07/2012
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(4) Measure the resistance between ECU connector X-462 pin 34 and TVA valve motor minus pin. The resis-
tance should be less than 10 Ω. Wiggle the harness during measurement to reveal an intermittent condition.
(5) Measure the resistance between ECU connector X-462 pin 8 and TVA position sensor supply pin. The
(6) Measure the resistance between ECU connector X-462 pin 53 and TVA position sensor signal pin. The
(7) Measure the resistance between ECU connector X-462 pin 37 and TVA position sensor ground pin. The
(2) Disconnect the TVA valve connector.
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3820-Over temperature error for H-bridge

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
ECU Power stages : Over temperature error on the TVA PWM output power stage
Cause:
The ECU detects an excess current draw on the TVA signal wire.
1. Faulty wiring
2. Faulty TVA valve
3. Faulty ECU
Solution:

RCPH11TLB089FAL 1

(3) TVA Valve X-470
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X-470
ply
nal
Ground
damage.
3. Measure the resistance through the wiring harness.
(3) Measure the resistance between ECU connector X-462 pin 49 and TVA valve motor plus pin. The resistance
4. Measure the resistance through the wiring harness to chassis ground.
B. The resistance is less than 20,000 Ω. There is a short circuit to chassis ground. Repair or replace the wire
5. Measure the resistance through the valve to chassis ground.
than 20,000 Ω.
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580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:
The TVA valve drive circuit is shorted to positive battery.

2. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
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RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
ply
nal
Ground
damage.
(2) Disconnect the TVA valve connector. Disconnect the ECU connector.
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47365539 08/07/2012
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580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:
The TVA valve drive circuit is shorted to positive battery.

2. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
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RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
ply
nal
Ground
damage.
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47365539 08/07/2012
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580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:
The TVA valve drive circuit or wiring is shorted to minus battery or chassis ground.

2. Faulty TVA valve
3. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
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RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
ply
nal
Ground
damage.
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(3) Measure the resistance from the TVA valve, motor plus pin to chassis ground. The resistance should be
RCPH11TLB091FAL 3

tance
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580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:

2. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
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RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
ply
nal
Ground
damage.
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RCPH11TLB099FAL 3
(1) ECU (4) TVA Valve

tance
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3825-Short circuit over load error for H-bridge

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The ECU had detected a short circuit in the TVA valve drive circuit.
Cause:
1. Wiring shorted.
2. Faulty TVA valve
3. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
47365539 08/07/2012
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RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
ply
nal
Ground
damage.
(2) Disconnect the TVA valve connector. Disconnect the TVA connector.
condition.
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55.DTC / 528
RCPH11TLB099FAL 3

tance
47365539 08/07/2012
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3826-Temperature dependent over current error for H-bridge

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Cause:
1. Wiring shorted.
2. Faulty TVA valve
3. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
47365539 08/07/2012
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RCPH11TLB089FAL 2

(3) TVA Valve X-470

X-470
ply
nal
Ground
damage.
(2) Disconnect the TVA valve connector. Disconnect the TVA connector.
condition.
47365539 08/07/2012
55.DTC / 531
RCPH11TLB099FAL 3

tance
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3827-Under voltage error for H-bridge

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
Under voltage error for H-bridge.
Cause:
The ECU had detected a high fluctuations in the system voltage.
1. Bad battery or battery connection

3. Faulty ECU
Solution:
rence.
RCPH11TLB007FAL 1
B. Fault code 3827 is recorded with other fault codes such as FC1014 or FC3051. Refer to Battery - Inspect
and clean (55.302), Battery - Test (55.302) and Alternator - Testing (55.301)
47365539 08/07/2012
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2. Inspect the battery cable connections.
(1) Verify that the battery terminals and battery cables are free of corrosion, abrasion and incorrect attachment.
(2) Verify that the battery chassis ground connection is clean and fastened securely to the frame. The chassis
connection point should be free of paint, rust, dirt and debris.
A. The cables and battery connections are secure and free of corrosion, abrasion and incorrect attachment.
Go to Step 3.
B. The battery connections or battery cables are in need of repair. Repair as required. Return to Step 1 to
(1) Inspect the ECU. All connections should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Battery to the ECU. Verify that the harness is free of damage, corrosion, abra-
sion and incorrect attachment.
A. The connectors are secure and the harness is free of damage. Temporarily replace the ECU and retest.
47365539 08/07/2012
55.DTC / 534
3838-Oxidation catalyst upstream temperature shorted to high

source
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected the exhaust gas temperature sensor #1 sensed voltage is above 5.2 V.
Cause:
The exhaust gas temperature sensor #1 signal is shorted to a high voltage source.

2. Faulty sensor
Solution:
rence.
RCPH11TLB007FAL 1

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RCPH11TLB080FAL 2
Schematic legend
(1) ECU (3) Exhaust Gas Temperature Sensor #2
(2) Exhaust Gas Temperature Sensor #1
(1) Inspect the ECU and the Exhaust Gas Temperature Sensor connections. All connections should be secure,
(2) Inspect the harness from the ECU to the Exhaust Gas Temperature Sensors. Verify that the harness is free
(2) Disconnect ECU connector X-461. Disconnect the Temperature Sensor #1 connector.
(3) Fabricate a jumper wire 20 cm (8 in) long. Use the jumper wire to short the Exhaust Gas Temperature Sensor
connector X-476 pin 1 to pin 2. Wiggle the harness during measurement to reveal an intermittent condition.
47365539 08/07/2012
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5. Measure the resistance of the ssensor.
(2) Disconnect the Temperature Sensor #1 connector.
(3) Measure the resistance of the Exhaust Gas Temperature Sensor pin 1 to pin 2. The resistance should be
B. The resistance is not within the specified range. Temporarily replace the Temperature Sensor and retest.
Go to Step 1 to confirm the elimination of the fault.
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3839-Oxidation catalyst upstream temperature shorted to low

source
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit ( ECU) has detected the exhaust gas temperature sensor #1 sensed voltage is less than 0.0
V.
Cause:
The exhaust gas temperature sensor #1 signal is shorted to a ground source.

2. Faulty sensor
Solution:
rence.
RCPH11TLB007FAL 1

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RCPH11TLB080FAL 2
Schematic legend
47365539 08/07/2012
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(3) Measure the resistance of the Exhaust Gas Temperature Sensor #1 pin 1 to chassis ground. The resistance
the sensor and retest. chassis ground. Go to Step 1 to confirm elimination of fault.
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3840-Diesel particulate filter upstream temperature sensor shorted

to high source
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected the exhaust gas temperature sensor #2 sensed voltage is above 6.55 V.
Cause:
The exhaust gas temperature sensor #2 signal is shorted to a high voltage source.

2. Faulty sensor
Solution:
rence.
RCPH11TLB007FAL 1

47365539 08/07/2012
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RCPH11TLB080FAL 2
Schematic legend
(3) Fabricate a jumper wire 20 cm (8 in) long. Use the jumper wire to short the Exhaust Gas Temperature Sensor
connector X-477 pin 1 to pin 2. Wiggle the harness during measurement to reveal an intermittent condition.
47365539 08/07/2012
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5. Measure the resistance of the ssensor.
(3) Measure the resistance of the Exhaust Gas Temperature Sensor pin 1 to pin 2. The resistance should be
B. The resistance is not within the specified range. Temporarily replace the Temperature Sensor and retest.
Go to Step 1 to confirm the elimination of the fault.
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55.DTC / 543
3841-Diesel particulate filter upstream temperature sensor shorted

to low source
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit ( ECU ) has detected the exhaust gas temperature sensor #2 sensed voltage is less than 0.0
V.
Cause:
The exhaust gas temperature sensor #2 signal is shorted to a ground source.

2. Faulty sensor
Solution:
rence.
RCPH11TLB007FAL 1

47365539 08/07/2012
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RCPH11TLB080FAL 2
Schematic legend
47365539 08/07/2012
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(3) Measure the resistance of the Exhaust Gas Temperature Sensor pin 1 to chassis ground. The resistance
the sensor and retest. Go to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 546
3844-3847-Zero Fuel Calibration by Lambda (ZFL) : DFC reporting

error state on comparing energizing time to Max value injector 1,
2, 3 or 4
Context:
This fault has been generated due to the injector (1, 2, 3 or 4) programming being incorrect. This failure can be the
result of wrong programming / flashing of the ECU or an internal defect of the injector. Using the Electronic Service
Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder. Repro-
gram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper data
set. If the error persists, replace the injector.
47365539 08/07/2012
55.DTC / 547
3848-3851-Zero Fuel Calibration by Lambda (ZFL) : DFC reporting

error state on comparing energizing time to Min value injector 1,
2 3 or 4
Context:
This fault has been generated due to the injector (cylinder 1, 2, 3 or 4) programming being incorrect. This failure can
be the result of wrong programming / flashing of the ECU or an internal defect of the injector. Using the Electronic
Service Tool (EST), Easy-Engine software, check the injector code matches the injector code used for that cylinder.
Reprogram the engine control unit (ECU) to the proper injector code. Try to flash the ECU correctly with the proper
data set. If the error persists, replace the injector.
47365539 08/07/2012
55.DTC / 548
3852-Lambda sensor: The maximum allowed time for blow out is

exceeded
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The heat up of the oxygen sensor is monitored by the ECU. If insufficient heater performance from the oxygen sensor
is detected for too long this fault code will occur. Replace the oxygen sensor.
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55.DTC / 549
3856-Coolant temperature signal test failure

580N T4, 580SN T4, 580SN WT T4, 590SN T4
NOTICE: Check coolant level before proceeding.
Cause:

Solution:
rence.

A. NOT OK – Repair fan or clear clogs from radiator. Return to Step 1 to confirm elimination of fault.
3. Check engine coolant temperature sensor.
BD08E033-01 1
(1) Connector coolant temperature sensor

(2) Upper radiator hose
(1) Disconnect the coolant temperature sensor. Inspect pins, wiring and connectors for damage, abrasion, cor-
rosion or incorrect attachment.
47365539 08/07/2012
55.DTC / 550
(2) Measure the resistance of the coolant temperature sensor. The resistance should be between 304 - 342 Ω
at 80 °C (176.0 °F), 2262 - 2760 Ω at 20 °C (68.0 °F), 8244 - 10661 Ω at -10 °C (14.0 °F) should be obtained.
A. NOT OK – Replace sensor. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance through the wires.
(1) Measure the resistance from coolant temperature sensor pin 2 to ECU connector X-462, pin 57. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
(2) Measure the resistance from coolant temperature sensor pin 1 to ECU connector X-462, pin 57. The resis-
tance should be less than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
of fault.
for assistance.
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3899-Info: Engine temperature exceeded pre-warn level

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This fault is caused when the engine temperature is getting to high. This fault can be caused by a cooling system
correct amount of coolant. Make sure the radiator is not clogged or is restricted of air flow. Also, check the thermostat
is not stuck. Once everything has been checked, if everything is correct, erase the fault code.
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55.DTC / 552
3900-Info: Engine temperature exceeded warn level

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This fault is caused when the engine temperature is getting to high. This fault can be caused by a cooling system
correct amount of coolant. Make sure the radiator is not clogged or is restricted of air flow. Also, check the thermostat
is not stuck. Once everything has been checked, if everything is correct, erase the fault code.
47365539 08/07/2012
55.DTC / 553
3906-Injector: Number of injections is limited by quantity balance

of high pressure pump
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
This fault is caused when the number of desired injections is greater than maximum possible number of injection
per work cycle depending on high pressure pump maximum delivery capacity. If this fault has occurred, check for
other faults related to rail pressure deviation or fuel delivery. If any of those faults are active, correct those faults to
determine if they have corrected this fault. If no other faults are present, check fuel temperature. If temperature is
incorrect, allow for machine to rest to ambient temperature. If fuel temperature is good, check the high pressure pump
is working correctly. If the high pressure pump is determined to be worn out, replace the high pressure pump.
47365539 08/07/2012
55.DTC / 554
3910-Fuel metering unit: Error check for loose contact between

metering unit (MeUn) and ECU
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected a loose contact in the wiring of the metering unit. This can result in a
malfunction of the metering unit and lead to fuel pressure oscillations. Check all connections between fuel metering
unit to the ECU are good. Remove connectors and check that the pins are not bent or corroded. Check the wiring
harness is not damaged. If any damaged or issues are found, repair/replace damaged connectors, or wiring. Use a
multi-meter to measure the resistance of the fuel metering solenoid from pin 1 to pin 2. There should be approximately
3.2 Ω. If the coil resistance is not correct, replace the fuel metering unit.
47365539 08/07/2012
55.DTC / 555
3915-Pressure Relief Valve: Averaged rail pressure is outside the

expected range with open PRV
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has determined that the Pressure Relief Valve (PRV) is not opening completely or there
is a restriction at the PRV connections. Remove the PRV valve and check for any damages. If PRV is damaged,
replace the valve.
47365539 08/07/2012
55.DTC / 556
3916-Pressure Relief Valve: Open time of PRV for wear out

monitoring had exceeded maximum value
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Context:
The engine control unit (ECU) has detected the rail pressure is not stable. Check for other faults associated with rail
pressure. If other faults exist, first correct those faults and then determine if this fault has been corrected. Ensure the
pressure relief valve is securely tight.
47365539 08/07/2012
55.DTC / 557
3998-Unknown error
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
1. CAN communication interrupted during normal operation.

Solution:
1. Verify that the fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes .
rence.
(1) Turn ignition switch to RUN position.

3. (1) Use the "EASY" program in the EST tool to bring up the fault.
(2) The fault number will be unique for the engine controller.
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(3) Use the fault description to analyze the error, contact Technical Services Group for assistance.
(4) If no text or unique engine controller fault is found but the fault still appears on the AIC, contact Technical
Services Group for assistance.
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55.DTC / 559
3999-Unknown error
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:

Solution:
rence.

3. (1) Use the "EASY" program in the EST tool to bring up the fault.
(2) The fault number will be unique for the engine controller.
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(3) Use the fault description to analyze the error, contact Technical Services Group for assistance.
(4) If no text or unique engine controller fault is found but the fault still appears on the AIC, contact Technical
47365539 08/07/2012
55.DTC / 561
4000-Power supply (pin 2), forward FWD drive (pin 3), or RVS drive
(pin 4) drive shorted to ground H-type and S-type transmission
580N Powershift, 580N T4, 580SN Powershift, 580SN T4, 580SN WT Powershift, 580SN WT T4, 590SN Powershift, 590SN T4
Context:
The FNR (Forward-Neutral-Reverse) Switch provides the "In Gear" signal to the Trax control. The Trax control will
turn on the forward solenoid or the reverse solenoid based on the "In Gear" input and the "Forward" or the "Reverse"
input signals. While this fault is active, the transmission will shift into Neutral and the Instrument Cluster will illuminate
the Danger Lamp .
Cause:
The Trax control does not see 12 V on X-300 pin 2 or the forward solenoid, X-300 pin 3 or reverse solenoid, X-300
pin 4 outputs are shorted to ground.
1. Faulty wiring or connectors.

2. The "In Gear" signal is not present on Trax connector X-300, pin 2. "In Gear" signal wiring or circuit is open.
3. The Forward Solenoid signal wire, ( X-300 pin 3) is shorted to chassis ground.
4. The Reverse Solenoid signal wire, ( X-300 pin 4) is shorted to chassis ground.
5. Faulty Trax control
Solution:
rence.
RCPH11TLB007FAL 1
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BD08E025-01 2
RCPH10TLB086AAM 3
(1) Transmission controller

(2) Windshield washer reservoir
TRAX Controller Description Wire ID

X-300 connector
2 In Gear Signal 5207 YE
3 Forward solenoid signal/supply 3053 WH
4 Reverse solenoid signal/supply 3063 WH
12 Forward solenoid return 3073 GY
16 Neutral Signal 21C7 YE
18 Forward Signal 25A5 LB
40 Reverse solenoid return 3083 GY
46 Reverse Signal 25B6 LB
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RCPH11TLB026GAL 4
Schematic legend
(1) FNR Switch (4) TRAX Controller
(2) Forward Solenoid (5) S-Type Transmission
(3) Reverse Solenoid (6) H-Tyoe Transmission
(1) Inspect the connections to the FNR Switch, Connector X-147 and Connector X-040 / X-150 and X-300 on
the Trax control. All connections should be secure and tight.
(2) Inspect the harness from the FNR switch to the Trax Control. Verify that the harness is free of damage,
A. OK – Go to Step 3.
B. NOT OK – Repair or replace harness or connectors as needed. Return to Step 1 to confirm elimination of
fault.
3. Measure at voltage at the Trax Control.
(1) Lift the floor board to expose the Trax control.
(3) Place the FNR Switch in the Forward position.
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(4) Measure the voltage from X-300 pin 2 to X-300 pin 29 (chassis ground). The voltage should be between 12
V and 14 V. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage is correct, go to Step 4.
B. NOT OK – Go to Step 7
4. Measure the resistance of the Forward and Reverse solenoid circuits.
(2) Disconnect X-345 / X-374 .
A. OK – The resistance measurement was greater then 20,000 Ω. Go to Step 5.
B. NOT OK – The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the harness.
Repair or replace the faulty wire as needed. Return to Step 1 to confirm elimination of fault.
5. Measure the resistance of the Forward and Reverse solenoid circuits.
(1) Measure the resistance from X-374 A2 to chassis ground. The resistance should be greater than 20,000 Ω.
(2) Measure the resistance from X-374 A3 to chassis ground. The resistance should be greater than 20,000 Ω.
A. OK – The resistance measurement was greater then 20,000 Ω. Go to Step 6.
B. NOT OK – The resistance is less than 20,000 Ω. There is a short circuit to chassis ground in the harness.
Repair or replace the faulty wire as needed. Return to Step 1 to confirm elimination of fault.
6. Measure the resistance through the solenoid drive circuit.
(1) Measure the resistance between X-374 A2 and X-374 A3. The resistance should be approximately 7.5 Ω.
(2) Measure the resistance between X-374 B2 and X-374 B3. The resistance should be approximately 7.5 Ω.
A. OK – The resistance is between 6.8 Ω and 8 Ω. Temporarily replace the Trax Control. Return to Step 1 to
B. NOT OK – The resistance is less than 6.5 Ω. Temporarily replace the solenoid and retest. Return to Step
7. Measure the voltage at the FNR Switch.
Use backprobes or a breakout harness to measure the voltage at the FNR switch.
FNR Connector Description Wire ID

1 No Connect
2 Gear Command 1 1901 YE
3 Gear Command 2 to comfort steer 3221 YE
4 Kick Down to Trax 3211 YE
5 Reverse Signal to Trax Control 25B2 LB
6 Neutral Signal to Trax Control 21C5 YE
7 Forward Signal to Trax Control 25A2 LB
8 Battery from X-040 / X-150 pin 21 - F-009 19E10 OG
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RCPH11TLB027GAL 5
Schematic Legend
(1) FNR (Forward-Neutral-Reverse) (3) Engine Harness
Switch
(2) Breakout Harness - Dealer pro-
vided
(1) Measure the voltage from FNR connector pin 7 to ground. The voltage should be approximately 12 V.
A. OK – The voltage is approximately 12 V. Go to Step 9.
B. NOT OK – The voltage is not correct or less than 12 V. Go to Step 8.

8. Measure the voltage to the FNR switch.
(1) Measure the voltage from the FNR connector, pin 8 to ground (chassis ground). The voltage should be
approximately 12 V.
A. OK – The voltage is approximately 12 V. Temporarily replace the FNR switch. Go to Step 1 to confirm
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B. NOT OK – The voltage is not correct or less than 12 V. Check the +B circuit to the switch. Verify fuse
F-009 is not blown. Repair as required.
9. Measure the voltage at X-147.
(1) Measure the voltage at X-147 pin 32 (diode side). The voltage should be approximately 12 V.
B. NOT OK – The voltage is not correct or less than 12 V. There is a problem in the signal wire from the FNR
switch to X-147 pin 32. Repair or replace the wire as required.
10. Measure the voltage at X-147
(1) Measure the voltage at X-147 pin 28. The voltage should be approximately 12 V.
B. NOT OK – Replace the wire/diode from X-147 pin 32 to X-147 pin 28.
11. Measure the voltage at connector X-040
(1) Measure the voltage at X-040 pin 13. The voltage should be approximately 12 V.
B. NOT OK – The voltage was not correct. There is a problem in circuit 5203 YE/ 5205 YE. Verify splice
SP-104 is in good condition.
12. Measure the resistance of the TRAX Key On signal
(1) Turn key switch OFF.
(2) Measure the resistance from X-150 pin 13 to X-300 pin 2. The resistance should be less than 10 Ω. Wiggle
A. OK – The resistance is less than 10 Ω. Temporarily replace the Trax Control and retest. Go to Step 1 to
B. NOT OK – The resistance is greater than 10 Ω. Replace the wire from X-150 pin 13 to X-300 pin 2. Go to
test Step1 to confirm elimination of the fault.
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4001-Power supply (pin 5), PWM 1 drive (pin 6), or PWM 2 drive (pin
7) drive shorted to ground H-type transmission
Context:
The Key Switch provides the "TRAX Key ON" signal to the Trax control. The Trax control will turn on the S2 Solenoid/
(PWM 1/3 Solenoid) based or the S3 Solenoid/ (PWM 2/4 Solenoid) based on the inputs to the control. While this
fault is active, the transmission will shift into Neutral and the Instrument Cluster will illuminate the Danger Lamp .
Cause:
The Trax control does not see 12 VDC on X-300 pin 5 or the S2 Solenoid/ (PWM 1/3 Solenoid), X-300 pin 6 or S3
Solenoid/ (PWM 2/4 Solenoid), X-300 pin 7 outputs are shorted to ground.

2. The "Trax Key On" signal is not present on Trax connector X-300, pin 5. "Trax Key On" signal wiring or circuit
is open.
3. The S2 Solenoid signal wire, (X-300 pin 6) is shorted to chassis ground.
4. The S3 Solenoid signal wire, (X-300 pin 7) is shorted to chassis ground.
5. The PWM 1/3 Solenoid signal wire, (X-300 pin 6) is shorted to chassis ground.
6. The PWM 2/4 Solenoid signal wire, (X-300 pin 7) is shorted to chassis ground.
Solution:
rence.
RCPH11TLB007FAL 1
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B. NOT OK – Fault code is recorded again. Go to Step 2.

BD08E025-01 2
RCPH10TLB086AAM 3
(1) Transmission controller

(2) Windshield washer reservoir

X-300 connector
5 TRAX Key ON 19ED OG
6 S2 Solenoid or PWM 1/3 Solenoid drive 3043 WH
signal
7 S3 Solenoid or PWM 2/4 Solenoid drive 3593 WH
signal
8 TRAX Key ON 19EC OG
13 PWM 1/3 Solenoid ground/return 3033 GY
34 TRAX Key ON 19EB OG
41 PWM 2/4 Solenoid ground/return 3603 GY
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RCPH11TLB028GAL 4
Schematic legend
(1) Key Switch (5) H-Type Transmission with Powershift
Jumper Harness
(2) S-Type Transmission (6) PWM 1/3 Solenoid (Powershift Transmis-
sion Only)
(3) S2 Solenoid (7) PWM 2/4 Solenoid (Powershift Transmis-
sion Only)
(4) S3 Solenoid (8) TRAX Control
(9) GND004 Cab Ground Side Console on
Loader Control
(1) Inspect the connections to the Key Switch, Connector X-012 and X-300 on the Trax control. All connections
should be secure and tight.
(2) Inspect the harness from the Key Switch to the Trax Control. Verify that the harness is free of damage,
B. NOT OK – The connectors or harness is damaged. Repair or replace harness or connectors as needed.
and 14.5 volts. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK TYPE 1 – The voltage is correct. go to Step 4 .
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B. OK TYPE 2 – The voltage is correct. go to Step 7 .
C. NOT OK – Go to Step 10
4. Measure the resistance of the S2 Solenoid and S3 Solenoid circuit to chassis ground.
(2) Disconnect X-300.
(3) Measure the resistance from X-300 pin 6 to chassis ground. The resistance should be approximately 7.25
(4) Measure the resistance from X-300 pin 7 to chassis ground. The resistance should be approximately 7.25
A. OK – The resistance measurement was approximately 7.5 ohms. Go to Step 6.
B. NOT OK – The resistance was less than 6.5 ohms. Go to Step 5.

5. Measure the resistance through the S2 Solenoid and S3 Solenoid.
(1) Disconnect solenoid connection 322-1 and 323-1.
(2) Measure the resistance from the solenoid to chassis ground. The resistance should be approximately 7.25
(3) Measure the resistance from X-374 A3 to chassis ground. The resistance should be greater than 20,000
A. OK – The measured resistance was between 6.5 ohms and 8 ohms. The solenoid is OK. There is a short
to chassis ground in the solenoid drive wire. Repair or replace the wire as needed. Go to Step 1 to confirm
B. NOT OK – The resistance is less than 6.5 ohms. There is a short circuit to chassis ground in the solenoid.
Replace the solenoid. Return to Step 1 to confirm elimination of fault.
6. Measure the resistance of the PWM 1/3 Solenoid and PWM 2/4 Solenoid circuit to chassis ground.
(1) Disconnect solenoid connections 322-1 and 323-1. Disconnect the TRAX Control X-300.
(2) Measure the resistance X-300 pin 6 to chassis ground. The resistance should be greater than 20,000 ohms.
(3) Measure the resistance X-300 pin 7 to chassis ground. The resistance should be greater than 20,000 ohms.
A. OK – The resistance is greater than 20,000 ohms. Temporarily replace the Trax Control. Return to Step
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit in the solenoid drive wire from
the Trax Control to the solenoid. Replace the wire. Return to Step 1 to confirm elimination of fault.
7. Measure the resistance through the solenoid wires.
(2) Disconnect the TRAX X-300 connector.
(3) Measure the resistance between X-300 pin 6 and X-300 pin 13. The resistance should be approximately
7.25 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
7.25 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The resistance is between 6.5 ohms and 8 ohms. Go to Step 8.
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B. NOT OK – The resistance is less than 6.5 ohms. Go to Step 9.

8. Measure the resistance of the solenoid drive wires to chassis ground.
A. OK – The resistance is greater than 20,000 ohms. Temporarily replace the TRAX Control. Go to Step 1
B. NOT OK – The resistance is less than 20,000 ohms. The signal wire has a short circuit to chassis ground.
Replace or repair the signal wire. Go to Step 1 to confirm elimination of the fault.
9. Measure the voltage at X147.
(1) Disconnect solenoid connection 322-1 and 323-1.
(2) Measure the between X-300 pin 6 and X-300 pin 13. The resistance should be greeter than 20,000 ohms.
(3) Measure the between X-300 pin 7 and X-300 pin 41. The resistance should be greeter than 20,000 ohms.
A. OK – The resistance is greater than 20,000 ohms. The solenoid in the circuit has a short circuit. Replace
the solenoid. Go to Step 1 to confirm elimination of the fault code.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit in the solenoid signal line and
solenoid return line. Repair as required. 1 to confirm elimination of the fault code.
(1) Measure the voltage at X-012 pin 3 to chassis ground. The voltage should be approximately 12 volts.
A. OK – The voltage is between 12 and 14.5 volts. There is a problem between X-12 pin 3 and X-300 pin 5.
Inspect fuse F-009. Inspect splice SP-67. Repair as required. Go to Step 1 to confirm elimination of the
fault.
B. NOT OK – The voltage is less than 12 volts. Go to Step 11.

11. Measure the voltage at the key switch.
(1) Measure the voltage at the key switch pin 3 (Ignition). The voltage should be approximately 12 volts.
A. OK – The voltage is between 12 and 14.5 volts. There is a problem between the key switch and X-012 pin
3. Inspect splice SP-012. Repair as required. Go to Step 1 to confirm elimination of the fault.

12. Measure the voltage input to the key switch.
(1) Measure the voltage at key switch connector pin 1 (Battery). The voltage should be approximately 12 volts.
A. OK – The voltage is between 12 and 14.5 volts. There is a problem with the key switch. Replace the key
switch. Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The voltage is less than 12 volts. There is a problem with the 12 volt supply to the key switch.
Inspect fuse F-025. Repair as required. Go to Step 1.
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4002-Power supply for digital outputs (pin 8) does not have power
H-type and S-type transmission
Context:
The power supply for the digital outputs on the Trax Control is not functioning. The transmission will shift into Limp
Home mode in 2nd gear, without modulation. While this fault is active, the Instrument Cluster will illuminate the Warn-
ing Lamp .
Cause:
The power supply for the digital outputs on the Trax Control is not functioning.
1. Open circuit to the Trax Control

2. Faulty Fuse F-009
3. Faulty Trax Control
Solution:
rence.
RCPH11TLB007FAL 1

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BD08E025-01 2
RCPH10TLB086AAM 3

X-300 connector
Key switch Description Wire ID

1 Battery P018 RD
2 Start 21A2 YE
3 Ignition 3001 OG
4 Accessory 4001 OG
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RCPH11TLB062FAL 4
Schematic legend
(1) Key Switch (3) Battery supply to key switch from fuse
F-025
(2) Trax Control
and 14.5 volts. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage is correct. Temporarily replace the Trax Control and retest. Go to Step 1 to confirm
B. NOT OK – The voltage is not correct. Go to Step 4.

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fault.


(1) Measure the voltage at key switch connector pin 1 (Battery). The voltage should be between 12 and 14.2
volts.
A. OK – The voltage is between 12 and 14.5 volts. There is a problem with the key switch. Replace the key
switch. Go to Step 1 to confirm elimination of the fault.
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4004-Battery voltage (Pin 34) voltage below 10 volts for 2.5 seconds
with engine speed above 900 rpm H-type and S-type transmission
Context:
Battery voltage (Pin 34) voltage below 10 volts for 2.5 seconds with engine speed above 900 RPM. While this fault is
active, the Instrument Cluster will illuminate the Warning Lamp .
Cause:
Battery voltage (Pin 34) voltage below 10 volts for 2.5 seconds with engine speed above 900 RPM.
1. Open circuit to the Trax Control

2. Faulty Fuse F-009
Solution:
rence.
RCPH11TLB007FAL 1

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BD08E025-01 2
RCPH10TLB086AAM 3

X-300 connector
Key switch Description Wire ID

1 Battery P018 RD
2 Start 21A2 YE
3 Ignition 3001 OG
4 Accessory 4001 OG
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RCPH11TLB062FAL 4
Schematic legend
(1) Key Switch (3) Battery to key switch from fuse F-025
(2) Trax Control
(3) Measure the voltage from X-300 pin 34 to X-300 pin 29 (chassis ground). The voltage should be between
12 and 14.5 volts. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The voltage is correct. Temporarily replace the Trax Control and retest. Go to Step 1 to confirm
B. NOT OK – Go to Step 4
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fault.


(1) Measure the voltage at key switch connector pin 1 (Battery). The voltage should be approximately 12 volts.
A. OK – The voltage is between 12 and 14.5 volts. There is a problem with the key switch. Temporarily
replace the key switch and retest. Go to Step 1 to confirm elimination of the fault.
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4005-Downshift delayed due to possible engine overspeed

condition H-type and S-Type transmission
NOTE: Informational code only for the S-Type transmission.
Cause:
Downshift delayed due to possible engine overspeed condition. Downshift was not accomplished because vehicle
speed is too high. This is an informational fault code and no further troubleshooting is required.
Solution:
1. Fault Code 4005 is displayed on the Instrument Cluster to warn the operator that the downshift was not accom-
plished due to excessive engine speed.
RCPH11TLB007FAL 1
The Warning Lamp will illuminate Amber and the LCD backlight will change from the normal backlight
to Amber.
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4006-FWD input (Pin 12) feedback circuit is reading current with

command H-type and S-type transmission
Context:
input signals.
Cause:
The Trax Control is measuring an excessive current in the FWD input (Pin 12) feedback circuit when the Forward
Solenoid is ON. The current on X-300 pin 12 is greater than 1.1 Amp.

2. Short circuit in the Forward Solenoid.
3. The Forward Solenoid return wire, (X-300 pin 12) shorted to a voltage source.
Solution:
Prior to clearing fault codes, record all fault codes, number of occurrences, and engine hours at last occurrence.
A. OK – The fault is not recorded again. Return the machine to service.
B. NOT OK – The fault code is recorded again. Go to Step 2.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB063FAL 3
Schematic legend
(1) S-Type Transmission (4) H-Type Transmission with Powershift
Jumper Harness
(2) Forward Solenoid (5) Trax Control
(3) Reverse Solenoid (6) Forward signal (input) to the Trax Control
(1) Inspect Trax connector X-300 and the Forward Solenoid connections. All connections should be secure,
tight, free of corrosion, abrasion and/or damage.
(2) Inspect the harness from the Trax Control to the Forward Solenoid. Verify that the harness is free of damage,
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B. NOT OK – The connectors or harness has damage. Repair or replace harness or connectors as required.
3. Measure the voltage on the solenoid return wire.
(2) Disconnect Trax connector X-300 and the Forward Solenoid connector X-320.
(4) Measure the voltage from X-300 pin 12 to chassis ground. The voltage should be less than 0.5 volts. Wiggle
A. OK – The voltage measurement is less than 0.5 volts. Go to Step 4.
B. NOT OK – The voltage is greater than 0.5 volts. There is a short circuit to another voltage source. Replace
the wire from X-300 pin 12 to the Forward Solenoid. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the Forward Solenoid.
(2) Disconnect connector X-320 from the Forward Solenoid.
(3) Measure the resistance of the solenoid. The resistance should be approximately 7.25 ohms.
A. OK – The resistance is between 6.5 ohms and 8 ohms. Temporarily replace the Trax. Control and retest.
B. NOT OK – The resistance is less than 6.5 ohms. The Forward Solenoid has an internal short circuit.
Replace the Forward Solenoid and retest. Return to Step 1 to confirm elimination of fault.
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4007-FWD input (Pin 12) current is too low with command present
Context:
input signals.
Cause:
The Trax Control is measuring current in the FWD input (Pin 12) feedback circuit that is too low when the Forward
Solenoid is ON. The current on X-300 pin 12 is less than 0.05 Amp.

2. The Forward Solenoid drive or return wire has an open circuit.
3. Forward Solenoid has an internal open circuit.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB063FAL 3
Schematic legend
Jumper Harness
(1) Inspect Trax connector X-300 and the Forward Solenoid connections. All connections should be secure and
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3. Measure the resistance through the wire.
(2) Disconnect Trax connector X-300.
(3) Measure the resistance from X-300 pin 3 to X-300 pin 12. The resistance should be approximately 7.25
A. OK – The resistance is between 6.5 ohms and 8 ohms. Temporarily replace the Trax Control and retest.
Go to Step 1 to confirm the elimination of the fault. .
B. NOT OK – The resistance is greater than 8 ohms. There is a problem in the solenoid circuit. Go to Step 4.
B. NOT OK – The resistance is greater than 8 ohms. The Forward Solenoid has an internal open circuit.
(1) Disconnect X-300 and the Forward Solenoid connector, X-320.
(2) Fabricate a 5 inch jumper wire with pins on each end. Insert the jumper in connector X-320 pin 1 and X-320
pin 2.
(3) Measure the resistance between X300 pin 3 and X-300 pin 12. The resistance should be less than 10 ohms.
A. OK – The resistance is less than 10 ohms. Temporarily replace the Trax Control and retest. Go to Step 1
B. NOT OK – There is an open circuit in the harness. Inspect connectors from the Trax Control to the Forward
solenoid. Verify all connections are tight and secure and free of damage. Repair or replace the wires as
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4008-FWD solenoid is drawing more current than commanded

Context:
input signals.
Cause:
The Trax Control is measuring an excessive current in the FWD input (Pin 12) feedback circuit when the Forward
Solenoid is ON.

2. Short circuit in the Forward Solenoid.
3. The Forward Solenoid return wire, (X-300 pin 12) is shorted to a voltage source.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB063FAL 3
Schematic legend
Jumper Harness
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(2) Disconnect Trax connector X-300 and the Forward Solenoid connector X-320.
B. NOT OK – The resistance was less than 6.5 ohms. The Forward Solenoid has an internal short circuit.
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4009-FWD solenoid is drawing less current than commanded

Context:
input signals.
Cause:
The Trax Control is measuring current in the FWD input (Pin 12) feedback circuit that is too low when the Forward
Solenoid is ON. The machine will go into Limp Home mode (without modulation) in gear 2 only.

2. The Forward Solenoid drive or return wire has an open circuit.
3. Forward Solenoid has an internal open circuit.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB063FAL 3
Schematic legend
Jumper Harness
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B. NOT OK – The resistance is greater than 8 ohms. The Forward Solenoid has an internal open circuit.
(1) Disconnect X-300 and the Forward Solenoid connector, X-320.
(2) Fabricate a 5 inch jumper wire with Deutsch pins on each end. Insert the jumper in connector X-320 pin 1
and X-320 pin 2.
B. NOT OK – There is an open circuit in the harness. Inspect connectors from the Trax Control to the Forward
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4011-RVS input (pin 40) feedback circuit is reading current with

command H-type and S-type transmission
Context:
input signals.
Cause:
The Trax Control is measuring an excessive current in the REV input (Pin 40) feedback circuit when the Reverse
Solenoid is ON. The current on X-300 pin 40 is greater than 1.1 Amp.

2. Short circuit in the Reverse Solenoid.
3. The Reverse Solenoid return wire, (X-300 pin 40) is shorted to a voltage source.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
46 Reverse Signal 25A6 LB
RCPH11TLB063FAL 3
Schematic legend
Jumper Harness
(3) Reverse Solenoid (6) Reverse signal (input) to the Trax Control
(1) Inspect Trax connector X-300 and the Reverse Solenoid connections. All connections should be secure and
(2) Inspect the harness from the Trax Control to the Reverse Solenoid. Verify that the harness is free of damage,
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(2) Disconnect Trax connector X-300 and the Reverse Solenoid connector X-321.
the wire from X-300 pin 40 to the Reverse Solenoid. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the Reverse Solenoid.
(2) Disconnect connector X-321 from the Reverse Solenoid.
B. NOT OK – The resistance was less than 6.5 ohms. The Reverse Solenoid has an internal short circuit.
Replace the Reverse Solenoid and retest. Return to Step 1 to confirm elimination of fault.
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4012-RVS input (pin 40) current is too low with command present
Context:
input signals.
Cause:
The Trax Control is measuring current in the REV input (Pin 40) feedback circuit that is too low when the Reverse
Solenoid is ON. The current on X-300 pin 40 is less than 0.05 Amp.

2. The Reverse Solenoid drive or return wire has an open circuit.
3. Reverse Solenoid has an internal open circuit.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB063FAL 3
Schematic legend
Jumper Harness
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B. NOT OK – The resistance is greater than 8 ohms. The Reverse Solenoid has an internal open circuit.
(1) Disconnect X-300 and the Reverse Solenoid connector, X-321.
and X-321 pin 2.
B. NOT OK – There is an open circuit in the harness. Inspect connectors from the Trax Control to the Reverse
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4013-RVS solenoid is drawing more current than commanded

Context:
input signals.
Cause:
The Trax Control is measuring an excessive current in the REV input (Pin 40) feedback circuit when the Reverse
Solenoid is ON.

2. Short circuit in the Reverse Solenoid.
3. The Reverse Solenoid return wire, (X-300 pin 40) is shorted to a voltage source.
Solution:
rence.

BD08E025-01 1
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RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB063FAL 3
Schematic legend
Jumper Harness
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55.DTC / 601
B. NOT OK – The connectors or the harness is damaged. Repair or replace the harness or connectors as
needed. Return to Step 1 to confirm elimination of fault.
(2) Disconnect Trax connector X-300 and the Reverse Solenoid connector X-321.
the wire from X-300 pin 12 to the Reverse Solenoid. Return to Step 1 to confirm elimination of fault.
B. NOT OK – The resistance was less than 6.5 ohms. The Reverse Solenoid has an internal short circuit.
47365539 08/07/2012
55.DTC / 602
4014-RVS solenoid is drawing less current than commanded H-type

and S-type transmission
Context:
input signals.
Cause:
The Trax Control is measuring current in the REV input (Pin 40) feedback circuit that is too low when the Reverse
Solenoid is ON. The machine will go into Limp Home mode (without modulation) in gear 2 only.

2. The Reverse Solenoid signal or return wire has an open circuit.
3. Reverse Solenoid has an internal open circuit.
Solution:
rence.

BD08E025-01 1
47365539 08/07/2012
55.DTC / 603
RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB063FAL 3
Schematic legend
Jumper Harness
47365539 08/07/2012
55.DTC / 604
needed. Return to Step 1 to confirm elimination of fault.
(3) Measure the resistance of the solenoid through connector X-321 pin 1 and pin 2. The resistance should be
approximately 7.25 ohms.
B. NOT OK – The resistance is greater than 8 ohms. The Reverse Solenoid has an internal open circuit.
(1) Disconnect X-300 and the Reverse Solenoid connector, X-321.
and X-320 pin 2.
B. NOT OK – There is an open circuit in the harness. Inspect connectors from the Trax Control to the Reverse
47365539 08/07/2012
55.DTC / 605
4016-First and third shift modulation solenoid input (pin 13)

feedback circuit is reading current without command H-type
transmission
Context:
First and third shift modulation solenoid input (pin 13) feedback circuit is reading too much current with command.
The machine will shift into Neutral while this fault is active.
Cause:
H-Type transmission only. First and third shift modulation solenoid input (pin 13) feedback circuit is reading too much
current with command.

2. Short circuit in the 1/3 Solenoid.
3. The 1/3 Solenoid return wire, (X-300 pin 13) is shorted to a voltage source.
Solution:
rence.

BD08E025-01 1
47365539 08/07/2012
55.DTC / 606
RCPH10TLB086AAM 2

X-300 connector
6 1/3 solenoid signal/supply 3043 WH
13 1/3 solenoid return 3033 GY
RCPH11TLB064FAL 3
Schematic legend
(1) 1/3 Solenoid (3) H-Type Transmission with Powershift
Jumper Harness
(2) 2/4 Solenoid (4) Trax Control
(1) Inspect Trax connector X-300 and the 1/3 Solenoid connections. All connections should be secure and tight
and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the 1/3 Solenoid. Verify that the harness is free of damage,
47365539 08/07/2012
55.DTC / 607
(2) Disconnect Trax connector X-300 and the 1/3 Solenoid connector X-382.
the wire from X-300 pin 13 to the 1/3 Solenoid and retest. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the 1/3 Solenoid.
(2) Disconnect connector X-382 from the 1/3 Solenoid.
B. NOT OK – The resistance was less than 6.5 ohms. The 1/3 Solenoid has an internal short circuit. Replace
the 1/3 Solenoid and retest. Return to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 608
4017-First and third shift modulation solenoid input (pin 13) current
is too low with command present H-type transmission
Context:
First and third shift modulation solenoid input (pin 13) feedback circuit, current feedback is too low with command.
The machine will shift into Neutral while this fault is active.
Cause:
H-Type transmission only. First and third shift modulation solenoid input (pin 13) feedback circuit, current feedback is
too low with command.

2. Open circuit in the 1/3 Solenoid.
3. The 1/3 Solenoid signal or return wire has an open circuit.
Solution:
rence.

BD08E025-01 1
47365539 08/07/2012
55.DTC / 609
RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB064FAL 3
Schematic legend
Jumper Harness
47365539 08/07/2012
55.DTC / 610
B. NOT OK – The resistance is greater than 8 ohms. The 1/3 Solenoid has an internal open circuit. Replace
(1) Disconnect X-300 and the 1/3 Solenoid connector, X-382.
pin 2.
B. NOT OK – The resistance is greater than 10 ohms, there is an open circuit in the harness. Inspect con-
nectors from the Trax Control to the 1/3 solenoid. Verify all connections are tight and secure and free of
damage. Repair or replace the wires as required. Return to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 611
4018-First and third shift modulation solenoid is drawing more

current than commanded H-type transmission
Context:
First and third shift modulation solenoid input feedback circuit, current feedback is too high with command. The ma-
chine will shift into Neutral while this fault is active.
Cause:
too high with command.

3. The 1/3 Solenoid return wire, (X-300 pin 13) shorted to a voltage source.
Solution:

BD08E025-01 1
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55.DTC / 612
RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB064FAL 3
Schematic legend
Jumper Harness
(1) Inspect Trax connector X-300 and the 1/3 Solenoid connections. All connections should be secure, tight,
free of corrosion, abrasion and/or damage.
47365539 08/07/2012
55.DTC / 613
B. NOT OK – The resistance is less than 6.5 ohms. The 1/3 Solenoid has an internal short circuit. Replace
47365539 08/07/2012
55.DTC / 614
4019-First and third shift modulation solenoid is drawing less

Context:
First and third shift modulation solenoid input feedback circuit, current feedback is too low with command. The ma-
chine will shift into Neutral while this fault is active.
Cause:
too low with the solenoid commanded to the On position.

2. The 1/3 Solenoid wiring has an open circuit.
4. Faulty Trax control.
Solution:

BD08E025-01 1
47365539 08/07/2012
55.DTC / 615
RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB064FAL 3
Schematic legend
Jumper Harness
47365539 08/07/2012
55.DTC / 616
(3) Measure the resistance from X-300 pin 6to X-300 pin 13. The resistance should be approximately 7.25
and X-382 pin 2.
B. NOT OK – The resistance is greater than 10 ohms. There is an open circuit in the harness. Inspect
connectors from the Trax Control to the 1/3 solenoid. Verify all connections are tight and secure and free
of damage. Repair or replace the wires as required. Return to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 617
4021-Second and fourth shift modulation solenoid input (pin

41) feedback circuit is reading current with command H-type
transmission
Context:
Second and fourth shift modulation solenoid input, (pin 41) feedback circuit is reading too much current with command
Cause:
H-Type transmission only. Second and fourth shift modulation solenoid input (pin 41) feedback circuit is reading too
much current when the solenoid is commanded ON..

3. The 2/4 Solenoid return wire, (X-300 pin 41) is shorted to a voltage source.
Solution:

BD08E025-01 1
47365539 08/07/2012
55.DTC / 618
RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB064FAL 3
Schematic legend
Jumper Harness
47365539 08/07/2012
55.DTC / 619
the wire from X-300 pin 41 to the 2/4 Solenoid and retest. Return to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 620
4022-Second and fourth shift modulation solenoid input (pin 41)

current is too low with command present H-type transmission
Context:
Second and fourth shift modulation solenoid input (pin 41) current is less than 0.05 A with more than 0.1 A commanded
for more than 250 ms.
Cause:
H-Type transmission only. Second and forth shift modulation solenoid input (pin 41) feedback circuit, current feedback
is too low with command. The transmission will go into Limp Home mode in first gear, without modulation.

2. The 2/4 Solenoid signal wire or return wire has an open circuit.
Solution:
rence.

BD08E025-01 1
47365539 08/07/2012
55.DTC / 621
RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB064FAL 3
Schematic legend
Jumper Harness
47365539 08/07/2012
55.DTC / 622
and X-383 pin 2.
B. NOT OK – The resistance is greater than 10 ohms, there is an open circuit in the harness. Inspect con-
nectors from the Trax Control to the 2/4 solenoid. Verify all connections are tight and secure and free of
damage. Repair or replace the wires as required. Return to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 623
4023-Second and fourth shift modulation solenoid is drawing more

Context:
Second and fourth shift modulation solenoid input feedback circuit, current feedback is too high with command. The
machine will shift into Neutral.
Cause:
H-Type transmission only. Second and fourth shift modulation solenoid input (pin 41) feedback circuit, current feed-
back is too high with command.

3. The 2/4 Solenoid return wire, (X-300 pin 41) shorted to a voltage source.
Solution:

BD08E025-01 1
47365539 08/07/2012
55.DTC / 624
RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB064FAL 3
Schematic legend
Jumper Harness
47365539 08/07/2012
55.DTC / 625
the wire from X-300 pin 41 to the 2/4 Solenoid. Return to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 626
4024-Second and fourth shift modulation solenoid is drawing less

Context:
Second and fourth shift modulation solenoid input feedback circuit, current feedback is too low with command. The
machine will shift into Neutral.
Cause:
H-Type transmission only. Second and fourth shift modulation solenoid input (pin 41) feedback circuit, current feed-
back is too low with the solenoid commanded to the On position.

2. The 2/4 Solenoid wiring has an open circuit.
Solution:

BD08E025-01 1
47365539 08/07/2012
55.DTC / 627
RCPH10TLB086AAM 2

X-300 connector
RCPH11TLB064FAL 3
Schematic legend
Jumper Harness
B. NOT OK – The connectors or harness has damage. Repair or replace the harness or connectors as
47365539 08/07/2012
55.DTC / 628
pin 2.
B. NOT OK – The resistance is greater than 10 ohms. There is an open circuit in the harness. Inspect
connectors from the Trax Control to the 2/4 solenoid. Verify all connections are tight and secure and free
of damage. Repair or replace the wires as required. Return to Step 1 to confirm elimination of fault.
47365539 08/07/2012
55.DTC / 629
4026-First / Third shift solenoid shorted to ground H-type

transmission
Context:
The 1/3 solenoid driver (output) is shorted to ground (chassis ground).
Cause:
H-Type Transmission Only - The 1/3 solenoid driver (output) is shorted to ground (chassis ground). The machine will
go into Limp Home Mode in second gear (without modulation).

2. The 1/3 Solenoid drive circuit shorted to ground (chassis ground).
3. 1/3 Solenoid has an internal short circuit.
Solution:

BD08E025-01 1

X-300 connector
47365539 08/07/2012
55.DTC / 630
RCPH11TLB064FAL 2
Schematic legend
Jumper Harness
BC08A418 3
(1) 2/4 PWM solenoid (5) 4 wheel drive solenoid

(2) Reverse solenoid (6) 2nd/4th solenoid
(3) Forward solenoid (7) Differential lock solenoid
(4) 1/3 PWM solenoid (8) 1st/3rd solenoid
(1) Disconnect Trax connector X-300 and 1/3 solenoid connector 382.
47365539 08/07/2012
55.DTC / 631
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the 1/3
solenoid drive circuit. Verify harness is free of abrasion and the connectors are not damaged. Repair or
4. Measure the resistance across the solenoid.
(1) Measure the resistance from solenoid connector 382 pin 1 to chassis ground. The resistance should be
A. OK – The resistance is greater than 20,000 ohms. Temporarily replace the Trax control and retest. Go to
B. NOT OK – The resistance is less than 20,000 ohms. Replace the 1/3 solenoid and retest. Return to Step
47365539 08/07/2012
55.DTC / 632
4027-Second / Fourth shift solenoid shorted to ground H-type

transmission
Context:
The 2/4 solenoid driver (output) is shorted to ground (chassis ground).
Cause:
H-Type Transmission Only - The 2/4 solenoid driver (output) is shorted to ground (chassis ground). The machine will

2. The 2/4 Solenoid drive circuit shorted to ground (chassis ground).
3. 2/4 Solenoid has an internal short circuit.
Solution:

BD08E025-01 1

X-300 connector
47365539 08/07/2012
55.DTC / 633
RCPH11TLB064FAL 2
Schematic legend
Jumper Harness
BC08A418 3

(1) Disconnect Trax connector X-300 and 2/4 solenoid connector 383.
47365539 08/07/2012
55.DTC / 634
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the 2/4
B. NOT OK – The resistance is less than 20,000 ohms. Replace the 2/4 solenoid and retest. Return to Step
47365539 08/07/2012
55.DTC / 635
4028-Differential lock or 4 wheel drive solenoid shorted to ground

Context:
The Differential Lock solenoid driver (output) or the 4WD solenoid driver (output) is shorted to ground (chassis ground).
Cause:
The Differential Lock solenoid driver (output) or the 4WD solenoid driver (output) is shorted to ground (chassis ground).

2. The Differential Lock solenoid driver (output) or the 4WD solenoid driver (output) circuit is shorted to ground
(chassis ground).
3. Differential Lock solenoid or the 4WD solenoid has an internal short circuit.
Solution:

BD08E025-01 1

X-300 connector
39 4WD solenoid signal/supply 25X3 WH
11 Differential Lock signal/supply 3573 WH
47365539 08/07/2012
55.DTC / 636
RCPH11TLB029GAL 2
Schematic legend
(1) S-Type Transmission Harness (4) Trax Control
(2) 4WD Solenoid (5) GND004 Cab Ground Side Console on
Loader Control
(3) Differential Lock Solenoid (6) H-Type Transmission with Powershift
Jumper Harness
(1) Inspect Trax connector X-300, 4WD Solenoid connector and Differential Lock solenoid connector. All con-
nections should be secure, tight, free of corrosion, abrasion and/or damage.
(2) Inspect the harness from the Trax Control to the 4WD and Differential Lock Solenoids. Verify that the harness
47365539 08/07/2012
55.DTC / 637
BC08A418 3

(1) Disconnect Trax connector X-300 and 4WD solenoid connector 326 (H-Type harness connector 386) and
Differential Lock solenoid connector 327 (H-Type harness connector 387).
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the
solenoid drive circuit. Verify that the harness is free of abrasion and the connectors are not damaged.
Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
(1) Measure the resistance from 4WD solenoid connector 326 (H-Type harness connector 386) pin 1 to chassis
ground. The resistance should be greater than 20,000 ohms.
(2) Measure the resistance from Differential Lock solenoid connector 327 (H-Type harness connector 387) pin
1 to chassis ground. The resistance should be greater than 20,000 ohms.
B. NOT OK – The resistance is less than 20,000 ohms. Replace the solenoid and retest. Return to Step 1 to
47365539 08/07/2012
55.DTC / 638
4029-Shifter Lever improperly connected, no power to pin 16,

pin 18, or pin 46 for more than 3 seconds H-type and S-type
transmission
Context:
Shift lever improperly connected, no power to pin 16, pin 18, or pin 46 for more than 3 seconds.
Cause:
The Trax Control is powered ON but is not receiving a signal on X-300 pin 16, pin 18, or pin 46. If the Trax Control
does not receive a signal on either of these pins for more than 3 seconds, the Trax Control will log the fault code and
shift the transmission into Neutral.
1. Faulty wiring or connectors to the FNR Shift Lever.

2. Faulty wiring or connectors from the FNR Shift Lever to the Trax Control.
3. 12 volt supply to the FNR Shift Lever.
4. Faulty FNR Shift Lever.
Solution:
rence.

BD08E039-01 1

1 No Connect
47365539 08/07/2012
55.DTC / 639

8 Battery from X-040/X-150 pin 21 - F-009 19E10 OG

X-300 connector
RCPH11TLB065FAL 2
Schematic legend
(1) Inspect Trax connector X-300 and the FNR Shift Lever connections. All connections should be secure and
(2) Inspect the harness from the Trax Control to the FNR Shift Lever. Verify that the harness is free of damage,
3. Measure the voltage at the FNR Shift Lever.
Use backprobes or a breakout harness (as shown below) to measure the voltage at the FNR switch.
47365539 08/07/2012
55.DTC / 640
BD08E055-01 3
RCPH11TLB027GAL 4
Schematic Legend
Switch
vided
47365539 08/07/2012
55.DTC / 641
(2) Measure the voltage from FNR connector pin 8 to chassis ground. The voltage should be approximately 12
volts.
A. OK – The voltage is between 12 and 14.2 volts. Go to Step 4.
B. NOT OK – The voltage is less than 12 volts. There is a problem with the voltage supply to the FNR Switch.
Verify that splices SP-062 and SP-067 are OK. Verify that the connections at X-040/150 and X-012 are
secure and free of damage. Verify that fuse F-009 is not blown. Repair or replace as required. Go to
Replace FNR selector. Return to Step 1 to confirm elimination of fault.
4. Measure the voltage of the switch output.
(2) Place the FNR switch in the Neutral position. Measure the voltage from pin 6 to chassis ground. The voltage
should be approximately 12 volts.
(3) Place the FNR switch in the Forward position. Measure the voltage from pin 7 to chassis ground. The voltage
should be approximately 12 volts.
(4) Place the FNR switch in the Reverse position. Measure the voltage from pin 5 to chassis ground. The
voltage should be approximately 12 volts.
B. NOT OK – One or more voltage reading was less than 12 volts. There is a problem in the FNR Shift Lever.
Temporarily replace the FNR Shift Lever and retest. Return to Step 1 to confirm elimination of fault.
5. Measure the voltage at the Trax Control connector.
(2) Place the FNR switch in the Neutral position. Measure the voltage from X300 pin 16 to chassis ground
(X300-29). The voltage should be approximately 12 volts.
(3) Place the FNR switch in the Forward position. Measure the voltage from X300 pin 18 to chassis ground
(4) Place the FNR switch in the Reverse position. Measure the voltage from X300 pin 46 to chassis ground
A. OK – The voltage is between 12 and 14.2 volts for all three readings. Temporarily repalce the Trax Control
B. NOT OK – One or more voltage reading was less than 12 volts. There is a problem in the harness from
the FNR Shift Lever to the Trax Control. Repair or replace the harness as required. Return to Step 1 to
47365539 08/07/2012
55.DTC / 642
4030-Shifter Lever malfunction: transmission in neutral receives

forward and neutral together H-type and S-type transmission
Context:
Shift lever malfunction; transmission in neutral position and receives a forward and neutral signal together for more
than 5 seconds.
Cause:
Shift lever malfunction; transmission is in the neutral position and receives a forward signal and a neutral signal to-
gether more than 5 seconds. The Trax Control will log the fault code and keep the transmission in the neutral position
while the fault is active.
1. Faulty wiring or connections from the FNR Shift Lever to the Trax Control.
2. The Neutral and Forward signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
47365539 08/07/2012
55.DTC / 643

X-300 connector
RCPH11TLB065FAL 2
Schematic legend
47365539 08/07/2012
55.DTC / 644
BD08E055-01 3
RCPH11TLB027GAL 4
Schematic Legend
Switch
vided
47365539 08/07/2012
55.DTC / 645
(2) Use a wire removal tool and remove wire pin 6 and pin 7 from the FNR connector.
RCPH11TLB030GAL 5
Schematic Legend
(1) FNR (Forward-Neutral-Reverse) (4) Remove wires from pin 6 and pin 7.
Switch
(2) Breakout Harness - Dealer pro- (5) Digital Volt Meter
vided
(3) Engine Harness (6) Chassis ground
(4) Place the FNR switch in the Forward position.
(5) Measure the voltage from pin 6 to chassis ground. The voltage should be less than 0.5 volts.
(6) Measure the voltage from pin 7 to chassis ground. The voltage should be approximately 12 volts.
A. OK – The voltage on pin 6 is less than 0.5 volts and the voltage on pin 7 is between 12 and 14.2 volts. Go
to Step 4.
47365539 08/07/2012
55.DTC / 646
B. NOT OK – The voltage on pin 6 is between 12 and 14.2 volts and the voltage on pin 7 is between 12 and
14.2 volts. Temporarily replace the FNR Shift Lever and retest. Return to Step 1 to confirm elimination of
fault.
(2) Disconnect X-300 from the Trax Control.
(3) Measure the resistance between X-300 pin 16 and X-300 pin 18. The resistance should be greater than
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit between X-300 pin 16 and
X-300 pin 18. Repair or replace the harness as required. Return to Step 1 to confirm elimination of fault.
(1) Remove the breakout tee from the harness and FNR switch.
(2) Reinstall pin 6 and an pin 7 in the FNR connector. Reconnect the FNR harness connector to the FRN switch.
(4) Place the FNR Switch in the Neutral position.
(6) Measure the voltage from X-300 pin 16 to chassis ground. The voltage should be approximately 12 volts.
A. OK – The voltage on pin 18 is less than 0.5 volts and the voltage on pin 16 is between 12 and 14.2 volts.
Temporarily replace the Trax Control and retest. Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The voltage on pin 18 is between 12 and 14.2 volts and the voltage on pin 16 is between 12
and 14.2 volts. There is a short circuit between X-300 pin 18 and X-300 pin 16. Repair or replace the
47365539 08/07/2012
55.DTC / 647
4031-Shifter Lever malfunction: transmission in neutral receives

reverse and neutral together H-type and S-type transmission
Context:
Shift lever malfunction; transmission in neutral position and receives a reverse and neutral signal together for more
than 5 seconds.
Cause:
Shift lever malfunction; transmission is in the neutral position and receives a reverse signal and a neutral signal to-
gether more than 5 seconds. The Trax Control will log the fault code and keep the transmission in the neutral position
while the fault is active.
2. The Neutral and Reverse signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
47365539 08/07/2012
55.DTC / 648

X-300 connector
RCPH11TLB065FAL 2
Schematic legend
47365539 08/07/2012
55.DTC / 649
BD08E055-01 3
RCPH11TLB027GAL 4
Schematic Legend
Switch
vided
47365539 08/07/2012
55.DTC / 650
RCPH11TLB030GAL 5
Schematic Legend
Switch
vided
(4) Place the FNR switch in the Reverse position.
to Step 4.
47365539 08/07/2012
55.DTC / 651
fault.
(2) Reinstall pin 5 and an pin 6 in the FNR connector. Reconnect the FNR harness connector to the FRN switch.
47365539 08/07/2012
55.DTC / 652
4032-Shifter Lever malfunction: transmission in forward receives

forward and reverse together H-type and S-type transmission
Context:
Shift lever malfunction; transmission in forward position and receives a forward and reverse signal together for more
than 5 seconds.
Cause:
Shift lever malfunction; transmission is in the forward position and receives a forward signal and a reverse signal
together for a period greater than 5 seconds. The Trax Control will log the fault code and keep the transmission in the
neutral position while the fault is active.
2. The Forward and Reverse signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
47365539 08/07/2012
55.DTC / 653

X-300 connector
RCPH11TLB065FAL 2
Schematic legend
47365539 08/07/2012
55.DTC / 654
BD08E055-01 3
RCPH11TLB027GAL 4
Schematic Legend
Switch
vided
47365539 08/07/2012
55.DTC / 655
RCPH11TLB030GAL 5
Schematic Legend
Switch
vided
A. OK – The voltage on pin 7 is between 12 and 14.2 volts and the voltage on pin 5 is less than 0.5 volts. Go
to Step 4.
47365539 08/07/2012
55.DTC / 656
fault.
(2) Reinstall pin 5 and an pin 7 in the FNR connector. Reconnect the FNR harness connector to the FNR switch.
(4) Place the FNR Switch in the Reverse position.
47365539 08/07/2012
55.DTC / 657
4033-Shifter Lever malfunction: transmission in reverse receives

forward and reverse together H-type and S-type transmission
Context:
Shift lever malfunction; transmission in reverse position and receives a forward and reverse signal together for more
than 5 seconds.
Cause:
Shift lever malfunction; transmission is in the reverse position and receives a forward signal and a reverse signal
together for a period greater than 5 seconds. The Trax Control will log the fault code and keep the transmission in the
neutral position while the fault is active.
2. The Forward and Reverse signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
47365539 08/07/2012
55.DTC / 658

X-300 connector
RCPH11TLB065FAL 2
Schematic legend
47365539 08/07/2012
55.DTC / 659
BD08E055-01 3
RCPH11TLB027GAL 4
Schematic Legend
Switch
vided
47365539 08/07/2012
55.DTC / 660
RCPH11TLB030GAL 5
Schematic Legend
Switch
vided
to Step 4.
47365539 08/07/2012
55.DTC / 661
fault.
(4) Place the FNR Switch in the Forward position.
47365539 08/07/2012
55.DTC / 662
4034-Shifter Lever malfunction: transmission in forward receives

neutral and forward together H-type and S-type transmission
Context:
Shift lever malfunction; transmission in forward position and receives a forward and neutral signal together for more
than 5 seconds.
Cause:
Shift lever malfunction; transmission is in the forward position and receives a forward signal and a neutral signal
together more than 5 seconds. The Trax Control will log the fault code and keep the transmission in the neutral
position while the fault is active.
2. The Neutral and Forward signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
47365539 08/07/2012
55.DTC / 663

X-300 connector
RCPH11TLB065FAL 2
Schematic legend
(1) Inspect Trax connector X-300 and the FNR Shift Lever connections. All connections should be secure, free
of corrosion, abrasion and damage.
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BD08E055-01 3
RCPH11TLB027GAL 4
Schematic Legend
Switch
vided
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RCPH11TLB030GAL 5
Schematic Legend
Switch
vided
to Step 4.
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fault.
(2) Reinstall pin 6 and pin 7 in the FNR connector. Reconnect the FNR harness connector to the FNR switch.
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4035-Shifter Lever malfunction: transmission in reverse receives

neutral and reverse together H-type and S-type transmission
Context:
Shift lever malfunction; transmission is in the reverse position and receives a reverse and neutral signal together for
more than 5 seconds.
Cause:
Shift lever malfunction; transmission is in the reverse position and receives a reverse signal and a neutral signal
together more than 5 seconds. The Trax Control will log the fault code and keep the transmission in the neutral
position while the fault is active.
2. The Neutral and Reverse signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
RCPH11TLB065FAL 2
Schematic legend
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BD08E055-01 3
RCPH11TLB027GAL 4
Schematic Legend
Switch
vided
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RCPH11TLB030GAL 5
Schematic Legend
Switch
vided
to Step 4.
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fault.
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4036-During transition from second to third gear, and Gear CMD_01

signal erratic or incorrect H-type and S-type transmission
Context:
The Trax Control measured 12 volts on Gear Command 1 (X-300 pin 19) when the shifting from 2nd gear to 3rd gear.
Cause:
During the shift from 2nd gear to 3rd gear, the Trax Control measured 12 volts on Gear Command 1 (X-300 pin 19)
when it should have measured 0 volts. The Trax Control will log the fault code and go into Limp Home Mode (2nd
gear) while the fault is active.
2. Gear Command 1 and Gear Command 2 signal wires are shorted together.
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
47 3/4 Gear Command (Gear Command 2) 3223 YE
RCPH11TLB066FAL 2
Schematic legend
(1) FNR Switch (4) 12 volt supply from fuse F-009
(2) Relay K-014 Comfort Steer Cutout Relay (5) Gear Command 1
(3) TRAX Controller (6) Gear Command 2
Commanded Gear Gear Command 1 - FNR switch pin 2 Gear Command 2 - FNR switch pin 3 -
- Output Output
1st 12 volts 0 volts
2nd 0 volts 0 volts
3rd 0 volts 12 volts
4th 12 volts 12 volts
3. Measure the voltage at the FNR Shift Lever in second gear.
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BD08E055-01 3
RCPH11TLB027GAL 4
Schematic Legend
Switch
vided
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(2) Use a wire removal tool to remove wire pin 2 and pin 3 from the FNR connector.
RCPH11TLB031GAL 5
Schematic Legend
Switch
vided
(4) Place the FNR switch into second gear.
A. OK – The voltage on pin 2 is less than 0.5 volts and the voltage on pin 3 is less than 0.5 volts. Go to Step
4.
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B. NOT OK – The voltage on pin 2 is between 12 and 14.2 volts or the voltage on pin 3 is between 12 and
fault.
4. Measure the voltage at the FNR Shift Lever in third gear.
(2) Place the FNR switch into third gear.
(4) Measure the voltage from pin 3 to chassis ground. The voltage should be approximately 12 volts
to Step 5.
fault.
5. Measure the resistance through the harness
(3) Measure the resistance between X-300 pin 47 and X-300 pin 19. Wiggle the harness during measurement
to reveal an intermittent condition. The resistance should be greater than 20,000 ohms.
A. OK – The resistance is greater than 20,000 ohms. Temporarily replace the Trax Controller and retest. Go
to Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short between pin 47 and pin 19. Repair
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4037-During transition from first to second gear, and Gear CMD_02

Context:
The Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47) when the shifting from 1st gear to 2nd gear.
Cause:
During the shift from 1st gear to 2nd gear, the Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47)
2. Gear Command 2 signal wire shorted to a voltage source.
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
RCPH11TLB066FAL 2
Schematic legend
- Output Output
2nd 0 volts 0 volts
3. Measure the voltage at the FNR Shift Lever in first gear.
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BD08E055-01 3
RCPH11TLB027GAL 4
Schematic Legend
Switch
vided
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RCPH11TLB031GAL 5
Schematic Legend
Switch
vided
(4) Place the FNR switch into first gear.
to Step 4.
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fault.
4. Measure the voltage at the FNR Shift Lever in second gear.
A. OK – The voltage on pin 2 is less than 0.5 volts and the voltage on pin 3 is less than 0.5 volts Go to Step 5.
B. NOT OK – The voltage on pin 2 is less than 0.5 volts and the voltage on pin 3 is between 12 and 14.2
volts. Temporarily replace the FNR Shift Lever and retest. Return to Step 1 to confirm elimination of fault.
to reveal an intermittent condition. The resistance should be greater than 20,000 ohms.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short between pin 47 and pin 19. Repair
6. Measure the voltage on X-300 pin 19.
(2) Disconnect X-300 and remove the breakout tee from the FNR connector.
(4) Measure the voltage from X-300 pin 19 to chassis ground. Wiggle the harness during measurement to reveal
an intermittent condition. The voltage should be less than 0.5 volts.
A. OK – The voltage is less than 0.5 volts. Temporarily replace the Trax Control and retest. Go to Step 1 to
B. NOT OK – The voltage is approximately 12 volts. The wire has a short circuit to another voltage source.
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4038-During transition from third to fourth gear, and Gear CMD_02

Context:
The Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47) when the shifting from 3rd gear to 4th gear.
Cause:
During the shift from 3rd gear to 4th gear, the Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47)
Solution:
rence.

BD08E039-01 1

1 No Connect
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X-300 connector
RCPH11TLB066FAL 2
Schematic legend
- Output Output
2nd 0 volts 0 volts
3. Measure the voltage at the FNR Shift Lever in third gear.
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BD08E055-01 3
RCPH11TLB027GAL 4
Schematic Legend
Switch
vided
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RCPH11TLB031GAL 5
Schematic Legend
Switch
vided
A. OK – The voltage on pin 2 is less than 0.5 volts and the voltage on pin 3 is between 12 and 14.2 volts Go
to Step 4.
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B. NOT OK – The voltage on pin 2 is less than 0.5 volts and the voltage on pin 3 is less than 0.5 volts.
Temporarily replace the FNR Shift Lever and retest. Return to Step 1 to confirm elimination of fault.
4. Measure the voltage at the FNR Shift Lever in fourth gear.
(2) Place the FNR switch into fourth gear.
A. OK – The voltage on pin 2 is between 12 and 14.2 volts and the voltage on pin 3 is between 12 and 14.2
volts Go to Step 5.
B. NOT OK – The voltage on pin 2 is between 12 and 14.2 volts and the voltage on pin 3 is less than 0.5
volts. Temporarily replace the FNR Shift Lever and retest. Return to Step 1 to confirm elimination of fault.
(3) Fabricate a jumper wire to short FNR connector pin 2 to pin 3.
RCPH11TLB067FAL 6
Schematic Legend
(1) FNR (Forward-Neutral-Reverse) (3) Jumper wire between pin 2 and pin
Switch 3.
(2) Engine Harness
to reveal an intermittent condition. The resistance should be less than 10 ohms.
A. OK – The resistance is less than 10 ohms. Temporarily replace the Trax Controller and retest. Go to Step
B. NOT OK – The resistance is greater than 10 ohms. There is an open circuit in Gear Command 1 or Gear
Command 2 circuit. Repair or replace the harness as required. Return to Step 1 to confirm elimination of
fault.
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4040-Transmission Controller Driveline Configuration H-type and

S-type transmission
Cause:
One or more parameters in the Transmission Control are not programmed.
1. The Transmission Control is not configured. The machine will go into Limp Home mode in first gear.
Solution:
1. Connect the Electronic Service Tool and configure all programmable parameters in the Transmission Control.
RCPH11TLB007FAL 1
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4041-Transmission output shaft frequency above 3000 Hz detected

Context:
The Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47) when the shifting from 3rd gear to 4th gear.
Cause:
During the shift from 3rd gear to 4th gear, the Trax Control measured 12 volts on Gear Command 2 (X-300 pin 47)
Solution:
rence.


X-300 connector
17 Sensor Common 0401 BL
25 Transmission Speed Signal 3301 BL
43 Transmission Temperature Signal 3431 YE
44 Transmission Pressure Switch 3441 YE
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RCPH11TLB032GAL 1
Schematic legend
(1) TRAX Controller (5) Transmission Pressure Switch - switch
closes when charge pressure = 9.5 bar
(138 psi) ± 1.5 bar (22 psi)
(2) Battery supply from fuse F-009 (6) Transmission Temperature Sensor
(3) S-Type Transmission Harness (7) Transmission Speed Sensor
(4) H-Type Transmission Jumper Harness
(1) Inspect Trax connector X-300 and the Transmission Speed Sensor connections. All connections should be
secure and tight and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the Transmission Speed Sensor. Verify that the harness is free
3. Check sensor of damage.
(1) Remove the sensor. The sensor is submerged in oil, care should be taken when removing the sensor so
minimal fluid is lost. Inspect the sensor for damage Remove all metal shaving from the sensor.
A. OK – The sensor is free of damage. Reinstall the speed sensor. Go to Step 4.
B. NOT OK – The sensor is damaged. Replace the sensor. Return to Step 1 to confirm elimination of fault.
4. Measure the sensor supply voltage.
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(2) Measure the voltage from Transmission Speed Sensor connector X330 (X-388) pin 3 to X330 (X-388) pin 2.
The voltage should be approximately 12 volts. Wiggle the harness during measurement to reveal an intermittent
condition.
A. OK – The voltage is between 11.0 and 14.2 volts. Go to Step 7.
B. NOT OK – The voltage is less than 11.4 volts or greater than 12.6 volts. Go to Step 5.
5. Measure the resistance through the sensor supply wire.
(2) Measure the resistance from X330 (X-388) pin 2 to X-300 pin 17. The resistance should be less than 10
A. OK – The resistance is less than 10 ohms. Go to Step 6.
B. NOT OK – The resistance is greater than 10 ohms. There is an open circuit in the harness. Repair or
replace the harness as required. Go to Step 1 to confirm elimination of fault.
6. Measure the supply voltage at connector X-344.
(2) Measure the voltage at X-344 pin B6. The voltage should be approximately 12 volts. Wiggle the harness
during measurement to reveal an intermittent condition.
B. NOT OK – The voltage is less than 11 volts. There is an open circuit in the wire from B6 to the sensor.
Repair or replace the wire. Go to Step 1 to confirm elimination of the fault.
7. Measure the resistance through the signal wire.
(2) Measure the resistance from X330 (X-388) pin 1 to X-330 pin 25. The resistance should be less than 10
B. NOT OK – The resistance is greater than 10 ohms. There is an open circuit in the sensor signal wire.
Repair or replace the wire. Go to Step 1 to confirm elimination of the fault.
8. Replace the sensor
(1) Slide the new copper washer over the sensor. Always use a new washer when installing a new transmission
speed sensor.
(2) Remove the sensor. The sensor is submerged in oil, care should be taken when removing the sensor so
minimal fluid is lost. Inspect the sensor for damage Remove all metal shaving from the sensor.
(3) Install the new sensor into the housing. Tighten nut to 25 N·m (18.4 lb ft).
(4) Reinstall the sensor connector and retest.
A. OK – The sensor has been replaced. The fault is not longer active. Stop.
B. NOT OK – The fault is still active. Temporarily replace the Trax Control and retest. Go to Step 1 to confirm
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4042-Temperature signal erratic or incorrect H-type and S-type

transmission
Context:
The transmission temperature changed more than 50 °C (122 °F) between samples.
Cause:
The transmission temperature changed more than 50 °C (122 °F) between samples. The RED telltale light will illumi-
nate while the fault is active.
1. Faulty wiring or connections from the Transmission Temperature Sensor to the Trax Control.
2. Faulty sensor
Solution:
rence.


X-300 connector
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RCPH11TLB032GAL 1
Schematic legend
(138 psi) ± 1.5 bar (22 psi)
(1) Inspect Trax connector X-300 and the Transmission Temperature Sensor connections. All connections
should be secure and tight and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the Transmission Termperature Sensor. Verify that the harness
3. Measure the resistance of the temperature signal wire.
(2) Measure the resistance from Transmission Temperature Sensor 329 (H-Type Transmission 389) pin 1 to
X-300 pin 43. The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal
an intermittent condition.
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B. NOT OK – The resistance is greater than 10 ohms. There is an open circuit in the wire. Repair or replace
the harness as required. Return to Step 1 to confirm elimination of fault.
4. Measure the resistance of the Temperature Sensor
(1) Measure the resistance of the temperature sensor.
Transmission Sensor Open Circuit Resistance Measurements

Temperature Resistance in ohms (± 10%)
110 °C (230 °F) 130 Ω
105 °C (221 °F) 151 Ω
100 °C (212 °F) 175 Ω
95 °C (203 °F) 202 Ω
92 °C (198 °F) 223 Ω
88 °C (190 °F) 258 Ω
85 °C (185 °F) 280 Ω
81 °C (178 °F) 323 Ω
78 °C (172 °F) 358 Ω
74 °C (165 °F) 412 Ω
68 °C (154 °F) 511 Ω
16 °C (61 °F) 4250 Ω
A. OK – The resistance is measurements are within the values from the table. Temporarily replace the Trax
Control and retest. Go to Step 1.
B. NOT OK – The resistance is measurements were not within range. Temporarily replace the temperature
sensor and retest. Go to Step 1 to confirm elimination of fault.
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4043-Temperature sensor input (Pin 43) is shorted to a ground

Context:
The transmission temperature signal input is shorted to ground.
Cause:
The transmission temperature signal input is shorted to ground.
2. Faulty sensor
Solution:
rence.


X-300 connector
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RCPH11TLB032GAL 1
Schematic legend
(138 psi) ± 1.5 bar (22 psi)
should be secure and tight and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the Transmission Temperature Sensor. Verify that the harness
3. Measure the resistance of the temperature signal wire to chassis ground.
chassis ground. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement
to reveal an intermittent condition.
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B. NOT OK – The resistance is less than 20,000 ohms. There is an short circuit to chassis ground. Repair

110 °C (230 °F) 130 Ω
105 °C (221 °F) 151 Ω
100 °C (212 °F) 175 Ω
95 °C (203 °F) 202 Ω
92 °C (198 °F) 223 Ω
88 °C (190 °F) 258 Ω
85 °C (185 °F) 280 Ω
81 °C (178 °F) 323 Ω
78 °C (172 °F) 358 Ω
74 °C (165 °F) 412 Ω
68 °C (154 °F) 511 Ω
16 °C (61 °F) 4250 Ω
Control and retest.. Go to Step 1.
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4044-Temperature sensor input (Pin 43) is open circuit or shorted

to a voltage above 5 volts H-type and S-type transmission
Context:
The transmission temperature signal input is voltage is above 5 volts.
Cause:
The transmission temperature signal input has an open circuit or the signal wire is shorted to another voltage source.
2. Faulty sensor
Solution:
rence.


X-300 connector
43 Transmission Temperature Signal 3431 YE 20GA
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RCPH11TLB032GAL 1
Schematic legend
(138 psi) ± 1.5 bar (22 psi)
should be secure, tight, free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the Transmission Temperature Sensor. Verify that the harness
3. Measure the resistance of the temperature signal wire.
(1) Turn the key switch OFF. Disconnect Trax Controller connector X-300 and Transmission Temperature Sensor
connector 329 (389).
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4. Measure the resistance of the temperature signal wire to battery.
(2) Measure the resistance from X-300 pin 43 to chassis ground. The voltage should be less than 0.5 volts.
A. OK – The voltage is less than 0.5 volts. Go to Step 5.
B. NOT OK – The voltage is greater than 0.5 volts. There is a short circuit to another voltage source. Repair

110 °C (230 °F) 130 Ω
105 °C (221 °F) 151 Ω
100 °C (212 °F) 175 Ω
95 °C (203 °F) 202 Ω
92 °C (198 °F) 223 Ω
88 °C (190 °F) 258 Ω
85 °C (185 °F) 280 Ω
81 °C (178 °F) 323 Ω
78 °C (172 °F) 358 Ω
74 °C (165 °F) 412 Ω
68 °C (154 °F) 511 Ω
16 °C (61 °F) 4250 Ω
Control and retest. Go to Step 1.
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55.DTC / 700
4045-Charge pressure is not detected when engine speed is above

700 rpm for 10 seconds H-type and S-type transmission
Context:
The Trax Control did not receive a Transmission Charge Pressure signal while engine speed is greater than 700 rpm
for a period greater than 10 seconds.
Cause:
The Trax Control did not receive a Transmission Charge Pressure signal when engine speed is greater than 700 rpm.
The transmission will shift into Neutral while this code is active.
2. Faulty Charge Pressure switch
Solution:
rence.


X-300 connector
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RCPH11TLB032GAL 1
Schematic legend
(138 psi) ± 1.5 bar (22 psi)
(1) Inspect Trax connector X-300 and the Transmission Pressure Switch connections. All connections should
be secure and tight and free of corrosion, abrasion and damage.
(2) Inspect the harness from the Trax Control to the Transmission Pressure Sensor. Verify that the harness is
free of damage, corrosion, abrasion and incorrect attachment.
3. Measure the resistance of the transmission pressure signal wire.
(1) Turn the key switch OFF. Disconnect Trax Controller connector X-300 and Transmission Pressure Sensor
(2) Measure the resistance from Transmission Pressure Sensor 328 (H-Type Transmission 390) pin 1 to X-300
44. The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal an inter-
mittent condition.
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pin 17. The resistance should be less than 10 ohms. Wiggle the harness during measurement to reveal an
4. Test the pressure switch.
(2) Remove the pressure switch from the transmission housing. Apply a pressure of 10 bar (145 psi) ± 1.5 bar
(22 psi) to the switch.
(2) Measure the resistance from terminal 1 to terminal 2 on the switch. The resistance should be less than 10
ohms while the pressure is applied.
B. NOT OK – The resistance is greater than 10 ohms. The switch is faulty. Replace the pressure switch.
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55.DTC / 703
4046-Charge pressure is not detected and vehicle speed is over 10

kph (6 mph) H-ype and S-type transmission
Context:
The Trax Control did not receive a Transmission Charge Pressure signal while vehicle speed is greater than 10 km/h
(6 mph) for a period greater than 0.5 seconds.
Cause:
The Trax Control did not receive a Transmission Charge Pressure signal while vehicle speed is greater than 10 km/h
(6 mph) for a period greater than 0.5 seconds.
1. Problem within the transmission.

Solution:
rence.

2. Check Charge Pressure
(1) Remove the pressure switch from the transmission housing.
(2) Install a gauge or use DATAR to measure the charge pressure. Charge pressure switch will be active when
the pressure is greater than 9.5 bar (138 psi). The measuring device should be capable of measuring 10 bar
without being damaged.
(3) Install the gauge. Monitor gauge pressure while operating the engine. a
A. OK – Charge pressure should be greater than 9.5 bar (138 psi) and the pressure switch should close. Go
to Step 3.
B. NOT OK – There is a problem with the transmission. Refer to the transmission section for more details.

X-300 connector
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RCPH11TLB032GAL 1
Schematic legend
(138 psi) ± 1.5 bar (22 psi)
47365539 08/07/2012
55.DTC / 705
5. Test the pressure switch.
(2) Remove the pressure switch from the transmission housing. Apply a pressure of 10 bar (145 psi) ± 1.5 bar
(22 psi) to the switch.
(3) Measure the resistance from terminal 1 to terminal 2 on the switch. The resistance should be less than 10
ohms while the pressure is applied.
B. NOT OK – The resistance is greater than 10 ohms. The switch is faulty. Replace the pressure switch.
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4047-Charge pressure switch is closed with no frequency input to

the TRAX controller H-type and S-type transmission
Context:
The Trax Control received a Charge Pressure Signal while engine speed equals 0 rpm.
Cause:
The Trax Control received a Charge Pressure Signal while engine speed equals 0 rpm. The Charge Pressure switch
is closed with no frequency input from the Transmission Speed sensor.
Solution:
rence.


X-300 connector
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RCPH11TLB032GAL 1
Schematic legend
(138 psi) ± 1.5 bar (22 psi)
3. Check Charge Pressure switch
(2) Disconnect the Charge Pressure Switch connector 328 (390).
(3) Measure the resistance between pin 1 and pin 2 on the Charge Pressure switch. The resistance should be
47365539 08/07/2012
55.DTC / 708
B. NOT OK – The resistance is less than 20,000 Replace the Charge Pressure switch. Go to Step 1 to
(2) Measure the resistance from Trax Control connector X-300 pin 44 to chassis ground. The resistance should
be greater than 20,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK – The resistance is less than 10 ohms. Temporarily replace the Trax Control and retest. Go to Step 1.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit in the wire to chassis ground.
47365539 08/07/2012
55.DTC / 709
4054-Unknown vehicle model value from VCM S-type transmission

Cause:
The transmission control does not recognize the vehicle model from the VCM. The Warning Lamp will illuminate
Amber and the LCD backlight will change from the normal backlight to Amber. The Instrument Cluster will sound the
alarm for one second upon activation per key cycle.
Solution:
1. Fault Code 4054 is displayed on the Instrument Cluster to warn the operator that the vehicle model has not been
programmed in the VCM. Set the model type in the machine configuration screen using the EST.
RCPH11TLB007FAL 1
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4100-Missing EEC 1 message on CAN H-type transmission

Context:
CAN Data Link communications between the Trax Control and the ECU have been lost
Cause:
CAN Data Link communications between the Trax Control and the ECU have been lost. The Trax Control did not
receive the EEC1 message from the ECU. This fault code may be displayed with other Trax CAN Data Link fault
messages indicating a failure in the Trax CAN Data Link circuit.
1. Power supply to the Trax Control.

3. Faulty wiring or CAN Data Link connections from the ECU to the Trax Control.
Solution:
last occurrence.
B. NOT OK – The fault code is recorded again. Go to Step 2.

(2) Verify the connections to the ECU, Instrument Cluster, TRAX Controller and Diagnostic Connector are tight
and secure.
(3) Verify the CAN Data Link connections from the ECU to the TRAX Control are tight and secure.
(4) Verify the harness is free of damage, abrasion, corrosion and incorrect attachment.
A. OK - The harness is not damaged and the connections are secure. Go to Step 3.
B. NOT OK - The harness or connectors have damage. Repair as required. Go to Step 1 to confirm elimi-
nation of fault.
3. Measure battery voltage at the Trax Control.
(2) Measure the voltage at the Trax Connector X-300 pin 1 to X-300 pin 29. The voltage should be approximately
12 volts.
A. OK - The voltage is between 12 and 14.2 volts. Go to Step 4.
B. NOT OK - The voltage is less than 12 volts. There is a problem with the battery supply to the Trax Control.
Verify fuse F-024 is not blown. Repair as required. Go to Step 1 to confirm elimination of fault.
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RCPH10TLB030FAM 1
Schematic Legend
(1) ECU Connector (5) Internal termination resistor, 120 ohms
(2) Instrument Cluster connector, X-29 (6) CAN Data Link LOW (Green Wire)
(3) Diagnostic Connector, X-009 (7) CAN Data Link HIGH (Yellow Wire)
(4) TRAX Controller, X-300
(2) Disconnect the Trax connector X-300. Measure the resistance from pin 55 on connector X-300 to chassis
ground. The resistance should be greater than 20,000 ohms. Wiggle the harness during measurement to reveal
(3) Measure the resistance from pin 27 on connector X-300 to chassis ground. The resistance should be greater
(4) Measure the resistance from pin 55 on connector X-300 to positive battery. The resistance should be greater
(5) Measure the resistance from pin 27 on connector X-300 to positive battery. The resistance should be greater
A. OK - All resistance measurements are greater than 20,000 ohms. Go to Step 5.
B. NOT OK - The resistance is less than 20,000 ohms. There is a short circuit in the CAN Data Link. Tem-
porarily replace the CAN Data Link wires and retest. Go to Step 1 to confirm elimination of the fault code.
(1) Turn the key switch OFF. Disconnect Trax Control connector X-300.
(2) Measure the resistance between X-300 pin 27 and pin 55. The resistance should be between 54 and 66
A. OK - The resistance is between 54 and 66 ohms. Temporarily replace the Trax Control and retest. Go to
B. NOT OK - The resistance is less than 54 ohms or the resistance is greater than 66 ohms, go to test Step 6.
6. Measure the resistance between CAN High and CAN Low wires.
47365539 08/07/2012
55.DTC / 712
(2) Disconnect the ECU and Instrument Cluster Data Link connectors.
A. OK - The resistance is greater than 20,000 ohms. Go to Step 7.
B. NOT OK - The resistance is less than 20,000 ohms. There is a short circuit between the CAN High and
CAN Low wires. Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
7. Measure the resistance of the CAN Circuit to the Instrument Cluster.
(1) Fabricate a jumper wire 15 cm (6 in) long.
(2) Use the jumper wire to short (connect) X-029 pin 4 to pin 3.
RCPH10TLB042FAM 2
Schematic Legend
(4) TRAX Controller, X-300 (8) Jumper wire to short pin 4 to pin 3
(3) Measure the resistance between Trax Connector X-300 pin 27 and 55. The resistance should be less than
10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - The resistance is less than 10 ohms. Go to Step 8.
B. NOT OK - The resistance is greater than 10 ohms. There is an open circuit in the CAN Data Link to the
Instrument Cluster. Repair or replace the harness as required. Go to step 1 to confirm elimination of the
fault.
8. Measure the resistance of the CAN Circuit to the engine ECU.
(1) Use the jumper wire to short (connect) ECM CAN Data Link connector pin 35 to pin 34.
47365539 08/07/2012
55.DTC / 713
RCPH10TLB043FAM 3
Schematic Legend
(4) TRAX Controller, X-300 (8) Jumper wire to short pin 34 to pin 35
(2) Measure the resistance between Trax Connector X-300 pin 27 and 55. The resistance should be less than
10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK - The resistance is less than 10 ohms. Temporarily replace the ECU and retest. Go to Step 1 to confirm
B. NOT OK - The resistance is greater than 10 ohms. There is an open circuit in the CAN Data Link to the
engine ECU. Repair or replace the harness as required. Go to step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 714
4101-Internal TRAX failure, hardware measurement H-type and

S-type transmission
Cause:
1. Internal error in Transmission Control.
Solution:
rence.

2. Replace transmission controller.
for assistance.
47365539 08/07/2012
55.DTC / 715
4102-Internal TRAX failure, software timing H-type and S-type

transmission
Cause:
1. Internal error in Transmission Control Module
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 716
4103-Internal TRAX failure, software not running H-type and S-type

transmission
Cause:
1. Internal failure inside Transmission Control Module
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 717
4105-Internal TRAX failure, redundant flash memory H-type and

S-type transmission
Cause:
1. Transmission Control Module internal error
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 718
4106-Internal TRAX failure, sensor supply high H-type and S-type

transmission
Context:
Trax Control 5 volt sensor output voltage is high.
Cause:
The Trax Control 5 volt sensor output is shorted to another voltage source.

Solution:
A. OK – Fault is not recorded again. Return the machine to service.


X-300 connector
15 5 Volt Supply 3151 PK
17 Signal Ground 0401 BL
45 Gear Switch 3/4 3451 YE
47365539 08/07/2012
55.DTC / 719
RCPH11TLB033GAL 1
Schematic legend
(1) Gear Switch 1 (5) 27k ohm resistor
(4) Gear Switch 4 (8) Trax Control
(1) Inspect Trax connector X-300 and the Gear switch connections. All connections should be secure, tight, free
of corrosion, abrasion and/or damage.
(2) Inspect the harness from the Trax Control to the Gear switches. Verify that the harness is free of damage,
3. Measure the voltage from X-300 pin 15 to chassis ground.
(2) Disconnect Trax Connector X-300.
A. OK – The voltage is less than 0.5 volts. Go to Step 4.
47365539 08/07/2012
55.DTC / 720
B. NOT OK – The voltage is greater than 0.5 volts. The wire is shorted to another voltage source. Repair or
4. Measure the resistance through the harness and resistor network
(2) Disconnect X-344/345.
(3) Disconnect Gear Switch connector 361.
(4) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 34.9k Ω
± 10%.
(5) Reconnect connector 361 and disconnect Gear Switch connector 360.
± 10%.
± 10%.
(10) Measure the resistance between X-345 B8 and X-345 A8. The resistance should be approximately 11.0k
Ω ± 10%.
Resistance measured with the sub harness disconnected from the vehicle harness
Gear Sw 1 Gear Sw 2 Gear Sw 3 Gear Sw 4 Pins B8/A8 Pins B1/A8 Pins B8/C8
Neutral Closed Closed Closed Closed 10.1k Ω 10.1k Ω 17.7k Ω
1ST Gear Open Closed Closed Closed 34.9k Ω 11.0k Ω 21.9k Ω
2ND Gear Closed Open Closed Closed 12.0k Ω 12.0k Ω 51.0k Ω
3RD Gear Closed Closed Open Closed 11.0k Ω 34.9k Ω 21.9k Ω
4TH Gear Closed Closed Closed Open 12.0k Ω 12.0k Ω 27.1k Ω
A. OK – The resistance values were within the limits defined in the table. Temporarily Replace the Trax
Control and retest. Go to Step 1 to confirm elimination of the fault.
B. NOT OK – The resistance values were not limits defined in the table. Temporarily replace the harness and
retest. Go to Step 1 to confirm elimination of fault.
5. Verify harness after repairs.
(1) Reconnect all loose connectors.
(2) Turn the key switch ON
(3) Use back probes or fabricate a breakout Tee and measure the voltage from X-300 pin 54 to chassis ground.
Refer to the table below for the prober gear switch positions and voltage measurements.
Voltage measured at Trax Control connector X-300

Gear Sw 1 Gear Sw 2 Gear Sw 3 Gear Sw 4 Voltage measured on Voltage measured on pin
pin 54 45
Neutral Closed Closed Closed Closed 3V 3V
1ST Gear Open Closed Closed Closed 1V 3V
2ND Gear Closed Open Closed Closed 4V 3V
3RD Gear Closed Closed Open Closed 3V 1V
4TH Gear Closed Closed Closed Open 3V 4V
47365539 08/07/2012
55.DTC / 721
47365539 08/07/2012
55.DTC / 722
4107-Internal TRAX failure, sensor supply low H-type and S-type

transmission
Context:
Trax Control 5 volt sensor output voltage is shorted to ground.
Cause:
The Trax Control 5 volt sensor output is shorted to ground.

Solution:


X-300 connector
47365539 08/07/2012
55.DTC / 723
RCPH11TLB033GAL 1
Schematic legend
3. Measure the resistance from X-300 pin 15 to chassis ground.
(2) Disconnect Trax Connector X-300.
47365539 08/07/2012
55.DTC / 724
B. NOT OK – The resistance is less than 20,000 ohms. The wire is shorted to chassis ground. Repair or
4. Measure the resistance through the harness and resistor newtork
± 10%.
± 10%.
± 10%.
Ω ± 10%.
A. OK – The resistance values were within the limits defined in the table. Temporarily Replace the Trax
Control and retest. Go to Step 1 to confirm elimination of the fault.
Voltage measured at Trax Control connector X-300 with reference to chassis ground.
pin 54 45
47365539 08/07/2012
55.DTC / 725
47365539 08/07/2012
55.DTC / 726
4200-First shift solenoid shorted to ground S-type transmission

Context:
The S1 solenoid driver (output) is shorted to ground (chassis ground).
Cause:
S-Type Transmission Only - The S1 solenoid driver (output) is shorted to ground (chassis ground). The machine will

2. The S1 Solenoid drive circuit shorted to ground (chassis ground).
3. S1 Solenoid has an internal short circuit.
Solution:


X-300 connector
9 S1 solenoid signal/supply 3043 WH
38 S4 solenoid return 3033 GY
47365539 08/07/2012
55.DTC / 727
RCPH11TLB068FAL 1
Schematic legend
(1) S1Solenoid (5) Connector X-344/ X-345
(2) S4 Solenoid (6) S2 Solenoid
(3) Trax Control (7) S3 Solenoid
(4) Cab Ground Side Console on Loader
Control
(1) Inspect Trax connector X-300 and the S1 Solenoid connections. All connections should be secure and tight
(2) Inspect the harness from the Trax Control to the S1 Solenoid. Verify that the harness is free of damage,
(1) Disconnect Trax connector X-300 and S1 solenoid connector 324.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the S1
4. Measure the resistance to chassis ground..
47365539 08/07/2012
55.DTC / 728
B. NOT OK – The resistance is less than 20,000 ohms. Replace the S1 solenoid and retest. Return to Step
47365539 08/07/2012
55.DTC / 729
4203-Fourth shift solenoid shorted to ground S-type transmission

Context:
The S4 solenoid driver (output) is shorted to ground (chassis ground).
Cause:
S-Type Transmission Only - The S4 solenoid driver (output) is shorted to ground (chassis ground). The machine will

2. The S4 Solenoid drive circuit shorted to ground (chassis ground).
3. S4 Solenoid has an internal short circuit.
Solution:


X-300 connector
9 S1 solenoid signal/supply 3043 WH
38 S4 solenoid return 3033 GY
47365539 08/07/2012
55.DTC / 730
RCPH11TLB068FAL 1
Schematic legend
(1) S1Solenoid (5) Connector X-344/ X-345
(2) S4 Solenoid (6) S2 Solenoid
(3) Trax Control (7) S3 Solenoid
(4) Cab Ground Side Console on Loader
Control
(1) Inspect Trax connector X-300 and the S4 Solenoid connections. All connections should be secure and tight
(2) Inspect the harness from the Trax Control to the S4 Solenoid. Verify that the harness is free of damage,
(1) Disconnect Trax connector X-300 and S4 solenoid connector 325.
B. NOT OK – The resistance is less than 20,000 ohms. There is a short circuit to chassis ground in the S4
47365539 08/07/2012
55.DTC / 731
B. NOT OK – The resistance is less than 20,000 ohms. Replace the S4 solenoid and retest. Return to Step
47365539 08/07/2012
55.DTC / 732
4204-System detects different gear than commanded S-type

transmission
Context:
Trax Control detects a different gear than commanded.
Cause:
The gear indicated by the shift rail position sensors is not consistent with the gear the Trax control is commanding.
1. Faulty wiring or connectors

2. Faulty gear switch
4. Mechanical problem inside transmission
Solution:


X-300 connector
6 S2 Solenoid 3043 WH
45 Gear Switch 3/4 signal 3451 YE
47365539 08/07/2012
55.DTC / 733
RCPH11TLB070FAL 1
Schematic legend
(2) Gear Switch 2 (9) S1 Solenoid
(5) 27k ohm resistor (12) S4 Solenoid
(6) 62k ohm resistor (13) SP-G11, Cab Ground Side Console on
Loader Control
(7) 12k ohm resistor
3. Monitor EST
(1) Connect EST.
(2) Turn the key switch ON, engine OFF. place the transmission into neutral.
(3) Monitor the S-type parameters related to the gear position switches and controls.
A. OK – All parameters are displayed correctly on the EST. Go to Step 4.
B. NOT OK – A fault code is generated, go to the proper troubleshooting procedure. Go to step 1 or the
corresponding troubleshooting procedure.
4. (1) Turn the engine on while monitoring the EST. Place the transmission in 1st gear. Monitor the EST screen
and diagnostic codes.
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55.DTC / 734
RCPH11TLB007FAL 2
RCPH11TLB008FAL 3
47365539 08/07/2012
55.DTC / 735
RCPH11TLB009FAL 4
RCPH11TLB010FAL 5
(2) Place the transmission in 2nd gear. Monitor the EST screen and diagnostic codes.
(3) Place the transmission in 3rd gear. Monitor the EST screen and diagnostic codes.
(4) Place the transmission in 4th gear. Monitor the EST screen and diagnostic codes.
A. OK – All parameters are within specs. There is a mechanical problem in the transmission. Go to Step 8.
B. NOT OK – There is a problem in the gear switch circuit. Replace the faulty gear switch. Go to Step 5.
5. Measure the resistance through the gear switch.
47365539 08/07/2012
55.DTC / 736
(2) Disconnect S1 solenoid connector 361. Measure the resistance through the switch. The resistance should
be less than 10 ohms.
A. OK – All resistance measurements were greater than 20,000 ohms. Go to Step 6.
B. NOT OK – One or more resistance measurements are less than 10 ohms. Replace the faulty gear switch.
6. Measure the resistance through the harness and resistor network
± 10%.
± 10%.
± 10%.
Ω ± 10%.
A. OK – The resistance values were within the limits defined in the table. Temporarily replace the Trax Control
47365539 08/07/2012
55.DTC / 737
Voltage measured at Trax Control connector X-300

pin 54 45
8. Measure shift rail position
(2) Remove the first and second shift rail plug (2) and the third and fourth shift rail plug (1) from the rear of the
transmission.
RCPH11TLB001GAL 6
47365539 08/07/2012
55.DTC / 738
(3) Measure the depth of the end of the rail (1) in relation to the edge of the transmission housing.
RCPH11TLB011FAL 7
Measurement Diagnosis
18 mm (0.709 in) Rail is in 1st or 3rd gear position.
29 mm (1.142 in) Neutral rail position
40 mm (1.575 in) Rail is in 2nd or 3rd gear position.
A. OK – The measurements are correct and all resistance values are correct. Temporarily Replace the Trax
Control and retest. Go to Step 1 to confirm elimination of fault.
B. NOT OK – The rail is out of position. Perform a pressure test to determine which rail is out of position.
47365539 08/07/2012
55.DTC / 739
4205-System can not engage required gear. (Engaged gear is

different than requested gear) S-type transmission
Context:
The TRAX cannot complete a commanded shift within 3 tries and goes back to the previously selected gear.
1. This code is seen when the SPS fails to make a shift and then returns to the gear that was previously selected.
For example, the customer shifts the FNR from 2ndto 3rd, but the SPS fails to make the shift and returns to 2nd.
2. If the gear position switches are malfunctioning the transmission may be making the shift, but the TRAX is
receiving false information from the switches, like in the case of the water in the connector.
3. Cold oil can cause the transmission to be unable to shift.
Solution:


X-300 connector
47365539 08/07/2012
55.DTC / 740
RCPH11TLB070FAL 1
Schematic legend
Loader Control
3. Refer to:
Powershift transmission external controls - Overview S-Type Transmission (21.135)
Powershift transmission external controls - Service instruction Shift Rail Position Testing — S-type
Transmission (21.135)
Powershift transmission external controls - Service instruction Shift Rail Position Physical Measure-
ment — S-Type Transmission (21.135).
47365539 08/07/2012
55.DTC / 741
4206-Gear engagement failed S-type transmission

Context:
The TRAX will attempt to shift into a gear 3 times. After the third attempt the transmission will shift into neutral and
fault code 4206 will become active.
Fault code 4206 is similar to fault code 4205, except that the transmission is unable to shift back into the previously
selected gear.
1. The length of each shifting attempt is based on the temperature of the transmission, and can be up to 6 seconds.
Solution:


X-300 connector
47365539 08/07/2012
55.DTC / 742
RCPH11TLB070FAL 1
Schematic legend
Loader Control
3. Refer to:
47365539 08/07/2012
55.DTC / 743
4207-1ST/2ND gear shift rail position reporting first gear at startup

S-type transmission
Context:
The shift rails should be in neutral when the unit first starts, all the gear position switches should be closed. These
fault codes indicate that the TRAX saw the transmission in gear upon startup, when it should be in neutral.
1. Verify that the gear position switch giving the fault is open. If the switch reads closed, then check for a harness/
resistor network issue.
2. If the switches and harness are functioning correctly, then the shift rail is out of position at start-up.
Solution:


X-300 connector
47365539 08/07/2012
55.DTC / 744
RCPH11TLB070FAL 1
Schematic legend
Loader Control
3. Refer to:
47365539 08/07/2012
55.DTC / 745
4208-1ST/2ND gear shift rail position reporting second gear at

startup S-type transmission
Context:
Solution:


X-300 connector
47365539 08/07/2012
55.DTC / 746
RCPH11TLB070FAL 1
Schematic legend
Loader Control
3. Refer to:
47365539 08/07/2012
55.DTC / 747
4209-3RD/4TH gear shift rail position reporting third gear at startup

S-type transmission
Context:
Solution:


X-300 connector
47365539 08/07/2012
55.DTC / 748
RCPH11TLB070FAL 1
Schematic legend
Loader Control
3. Refer to:
47365539 08/07/2012
55.DTC / 749
4210-3RD/4TH gear shift rail position reporting forth gear at startup

S-type transmission
Context:
Solution:


X-300 connector
47365539 08/07/2012
55.DTC / 750
RCPH11TLB070FAL 1
Schematic legend
Loader Control
3. Refer to:
47365539 08/07/2012
55.DTC / 751
4211-First and second gear sensor input shorted to ground S-type

transmission
Cause:
First and second gear sensor input to the Trax Control is shorted to ground.

Solution:


X-300 connector
47365539 08/07/2012
55.DTC / 752
RCPH11TLB033GAL 1
Schematic legend
(1) Inspect Trax connector X-300 and the gear switch connections. All connections should be secure, tight, free
(2) Inspect the harness from the Trax Control to the gear switches. Verify that the harness is free of damage,
3. Measure the resistance between the signal wire and ground.
(2) Disconnect the Trax Controller connector X-300.
(3) Measure the resistance between Trax Connector pin 54 and chassis ground. The resistance should be
greater than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK — The resistance is greater than 10 ohms. Go to Step 4.
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire to chassis ground.
47365539 08/07/2012
55.DTC / 753
(2) Use a suitable wire to short Gear Switch 2 connector, pin 1 to pin 2. Disconnect Gear Switch 1 connector
361 pin 1. Verify that the wire from pin 1 does not short to chassis ground or to Gear Switch connector pin 2.
(3) Disconnect the Trax Controller harness X-300.
A. OK — The resistance is 27,000 ohms ±10 percent. Temporarily replace the Trax Controller and retest. Go
B. Not OK — The resistance is less than 10 ohms. Go to Step 5.

(1) Disconnect the Trax Controller harness X-300 from the Sub Harness X-344/X-345.
(2) Measure the resistance between Sub Harness connector B1 and C8. The resistance should be approxi-
mately 27,000 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
A. OK — The resistance is 27,000 ohms ±10 percent. There is a short circuit in the harness between X-300
and X-344/X-345. Temporarily replace the harness and retest. Go to Step 1 to confirm elimination of fault.
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire, B1 to signal
ground. Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 754
4212-First and second gear sensor input voltage too high S-type
transmission
Cause:
First and second gear sensor input to the Trax Control is shorted to a voltage source. The Trax Control is measuring
a voltage greater than 4 volts of connector X-300 pin 54.

Solution:


X-300 connector
47365539 08/07/2012
55.DTC / 755
RCPH11TLB033GAL 1
Schematic legend
3. Measure the resistance between the signal wire and battery supply.
(3) Measure the resistance between Trax Connector pin 54 and battery supply. The resistance should be greater
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire to battery supply.
47365539 08/07/2012
55.DTC / 756

(2) Measure the resistance between Sub Harness connector B1 and A8. The resistance should be approxi-
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire, B1 to the 5 volt
sensor supply. Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 757
4213-Third and forth gear sensor input shorted to ground S-type

transmission
Cause:
Third and fourth gear sensor input to the Trax Control is shorted to ground.

Solution:


X-300 connector
47365539 08/07/2012
55.DTC / 758
RCPH11TLB033GAL 1
Schematic legend
3. Measure the resistance between the signal wire and ground.
(3) Measure the resistance between Trax Connector pin 45 and chassis ground. The resistance should be
greater than 10 ohms. Wiggle the harness during measurement to reveal an intermittent condition.
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire to chassis ground.
47365539 08/07/2012
55.DTC / 759

(2) Measure the resistance between Sub Harness connector B8 and C8. The resistance should be approxi-
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire, B1 to signal
ground. Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 760
4214-Third and forth gear sensor input voltage too high S-type
transmission

Solution:


X-300 connector
47365539 08/07/2012
55.DTC / 761
RCPH11TLB033GAL 1
Schematic legend
3. Measure the resistance between the signal wire and battery supply.
(3) Measure the resistance between Trax Connector pin 45 and battery supply. The resistance should be greater
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire to battery supply.
47365539 08/07/2012
55.DTC / 762

(2) Measure the resistance between Sub Harness connector B8 and A8. The resistance should be approxi-
B. Not OK — The resistance is less than 10 ohms. There is a short circuit in the signal wire, B8 to the 5 volt
sensor supply. Repair or replace the harness as required. Go to Step 1 to confirm elimination of the fault.
47365539 08/07/2012
55.DTC / 763
4825-Loss of TC1 message after 15 seconds H-type and S-type

transmission
Cause:
Wrong software in the Instrument Cluster. The sensitivity setting for the Forward, Neutral and Reverse has not been
programmed. The Warning Lamp will illuminate Amber and the LCD backlight will change from the normal
backlight to Amber. The Instrument Cluster will sound the alarm for one second upon activation per key cycle.
Solution:
1. Fault Code 4825 is displayed on the Instrument Cluster to warn the operator that the Forward, Neutral and
Reverse setting have not been programmed.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 764
4850-Possible detection wrong transmission type for installed

software H-type and S-type transmission
Cause:
Wrong transmission type is programmed in the Trax Control. The Warning Lamp will illuminate Amber and the
LCD backlight will change from the normal backlight to Amber. The Instrument Cluster will sound the alarm for one
second upon activation per key cycle.
Solution:
1. Fault Code 4850 is displayed on the Instrument Cluster to warn the operator that the wrong transmission type
has been programmed. This fault code may be active with 4022 and 4017.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 765
4995-Incorrect VCM configuration of transmission type H-type and

S-type transmission
Cause:
Incorrect VCM configuration of transmission type. Power Shuttle has been selected in the VCM.
Solution:
1.
Power Shuttle has been selected in the VCM. The Warning Lamp will illuminate Amber and the LCD back-
light will change from the normal backlight to Amber. The Instrument Cluster will sound the alarm for one second
upon activation per key cycle.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 766
4996-Electronic transmission offline or incorrect VCM configuration

of transmission type H-type and S-type transmission
Cause:
The Trax Control is offline or is not configured properly. The Warning Lamp will illuminate Amber and the LCD
backlight will change from the normal backlight to Amber. The Instrument Cluster will sound the alarm for one second
upon activation per key cycle.
Solution:
1. Fault Code 4996 is displayed on the Instrument Cluster to warn the operator that the transmission control is
offline or is not configured.
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 767
4997-Loss of messaging from Trax controller H-type and S-type

transmission
Context:
CAN Data Link communications between the Instrument Cluster and the ECU have been lost. The Instrument Cluster
did not receive the EEC1 message from the ECU. This fault code may be displayed with other CAN Data Link fault
messages. The Instrument Cluster will illuminate the Danger Lamp and will continually sound the audible
alarm. The Low Oil Pressure lamp will also turn on.
Cause:
The Instrument Cluster has stopped receiving CAN messages from the ECU. CAN Data Link communications be-
tween the Instrument Cluster and the ECU have been lost.

4. Faulty ECU
Solution:
last occurrence.
If three or more fault codes are active, 1051 through 1059, this is an indication of a problem in the CAN Data
Link circuit, continue with this procedure. If one or two CAN Data Link fault codes are active, this is an indication
of an intermittent connection in the CAN circuit. Check all wire and connector to verify they are secure and free
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 768
machine service.
RCPH11TLB034GAL 2
47365539 08/07/2012
55.DTC / 769
CAN Low X-029 pin 3
CAN Low X-498 pin D


nector pin D)
47365539 08/07/2012
55.DTC / 770
RCPH11TLB074FAL 3
CAN Low X-029 pin 3
CAN Low X-498 pin D
47365539 08/07/2012
55.DTC / 771
RCPH11TLB072FAL 4
CAN Low X-029 pin 3
CAN Low X-498 pin D
47365539 08/07/2012
55.DTC / 772
4998-Unknown transmission error code with amber lamp H-type

and S-type transmission
Context:
The Instrument Cluster received and error message that it did not recognize.
Cause:
The Instrument Cluster received and error message that it did not recognize. The Instrument Cluster will illuminate
the Amber warning lamp.
1. Incompatible software versions.
Solution:
rence.
RCPH11TLB007FAL 1

2. Update Instrument Cluster software
(1) Verify that the Instrument Cluster and Trax Control have the latest versions of software. Contact Technical
for assistance.
47365539 08/07/2012
55.DTC / 773
4999-Unknown transmission error code with red lamp H-type and

S-type transmission
Context:
The Instrument Cluster received and error message that it did not recognize.
Cause:
The Instrument Cluster received and error message that it did not recognize. The Instrument Cluster will illuminate
the Red warning lamp.
1. Incompatible software versions.
Solution:
rence.
RCPH11TLB007FAL 1

2. Update Instrument Cluster software
(1) Verify that the Instrument Cluster and Trax Control have the latest versions of software. Contact Technical
for assistance.
47365539 08/07/2012
55.DTC / 774
9001-Hour meter plausibility, internal error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
1. Instrument Cluster internal failure
Solution:
rence.

2. Replace instrument cluster.
for assistance.
47365539 08/07/2012
55.DTC / 775
9002-Hour meter RAM checksum failure, internal error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 776
9003-J1939 receive buffer overflow, internal error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 777
9004-EEPROM checksum failure, hour meter location 1, internal

error
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 778

error
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 779

error
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
1. Instrument Cluster internal error
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 780
9007-Abnormal reset watchdog time-out, internal error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 781
9008-A/D fault foot throttle, internal error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
rence.
RCPH11TLB007FAL 1

for assistance.
47365539 08/07/2012
55.DTC / 782
9009-A/D fault foot throttle power, internal error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
rence.
RCPH11TLB007FAL 1

for assistance.
47365539 08/07/2012
55.DTC / 783
9010-A/D fault hand throttle, internal error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
1. Verify that fault code is still active, refer to 0000 - Retrieving fault codes, Backhoes.
rence.
RCPH11TLB007FAL 1

for assistance.
47365539 08/07/2012
55.DTC / 784
9011-A/D fault foot throttle, internal error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
rence.
RCPH11TLB007FAL 1

for assistance.
47365539 08/07/2012
55.DTC / 785
9012-A/D fault, internal error

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Cause:
Solution:
rence.
RCPH11TLB007FAL 1

for assistance.
47365539 08/07/2012
55.DTC / 786
3047-Main Relay Failure - Short Circuit To Battery

580N T4, 580SN T4, 580SN WT T4, 590SN T4
Control Module : EDC

Cause:

Solution:
rence.

3. Check Power Relay No. 2 fuse.
RCPH10TLB301AAF 1
A. NOT OK – Replace fuse. Return to Step 1 to confirm elimination of fault. If fuse blows again, go to Step 4
4. Check ground circuit.
47365539 08/07/2012
55.DTC / 787
RCPH10TLB301AAF 2
(1) Power Relay #2
(1) Disconnect Power Relay number 2 connector. Inspect connector and wiring for corrosion, abrasion or incor-
rect attachment.
(2) Measure the resistance from pin 86 (pin 1) to ground. The resistance should be less than 10 ohms. Wiggle
A. NOT OK – Determine the break between connector and ground. Return to Step 1 to confirm elimination
of fault.
5. (1) Turn the key switch ON. Engine OFF.
(2) Take a voltage reading at pin 85 of the Power Relay 2 connector to pin E of the Ignition Switch connector.
The voltage should be approximately 12 V .
of fault.
6. Check circuit to Fuse Block.
RCPH10TLB302AAF 3
(1) Fuse block (2) Diagnostic Connector
(1) Take reading from pin 87 of Power Relay 2 connector to the Power Relay No. 2 fuse.
A. NOT OK – Determine the break between connector and fuse block. Return to Step 1 to confirm elimination
of fault.
B. OK – Replace Power Relay No. 2. If fault is recorded again contact Technical Services Group for assis-
tance.
47365539 08/07/2012
55.DTC / 788
3048-Main Relay Failure - Short Circuit to Ground

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Cause:

Solution:
rence.

3. Check Power Relay No. 2 fuse.
RCPH10TLB302AAF 1
(1) Fuse block (2) Diagnostic Connector
A. NOT OK – Replace fuse. Return to Step 1 to confirm elimination of fault. If fuse blows again, go to Step 4
4. Check ground circuit.
47365539 08/07/2012
55.DTC / 789
BD08F241-01 2
(1) Power Relay #2
(1) Disconnect Power Relay number 2 connector. Inspect connector and wiring for corrosion, abrasion or incor-
rect attachment.
(2) Measure the resistance from pin 86 (pin 1) to ground. The resistance should be less than 10 ohms. Wiggle
A. NOT OK – Determine the break between connector and ground. Return to Step 1 to confirm elimination
of fault.
5. (1) Turn the key switch ON. Engine OFF.
(2) Take a voltage reading at pin 85 of the Power Relay 2 connector to pin E of the Ignition Switch connector.
The voltage should be approximately 12 V .
of fault.
6. Check circuit to Fuse Block.
BD08E024-01 3
(1) Fuse block

(2) Diagnostic Connector
(1) Take reading from pin 87 of Power Relay 2 connector to the Power Relay No. 2 fuse.
A. NOT OK – Determine the break between connector and fuse block. Return to Step 1 to confirm elimination
of fault.
B. OK – Replace Power Relay No. 2. If fault is recorded again contact Technical Services Group for assis-
tance.
47365539 08/07/2012
55.DTC / 790
3108-Fuel Metering Unit - Short Circuit To Ground

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Context:
The engine control unit (ECU) has determined that a short to low source circuit condition exists in the fuel high pres-
sure pump low side circuit. The metering unit of the fuel high pressure pump regulates the pressure in the common
rail. The metering unit is closed-loop controlled by both main relay 1 (high side) and a low side power stage (Main
Relay 1 is an electronic control circuit within the ECU, providing source voltage to devices external to the ECU. The
low side power stage works in conjunction with the Main Relay 1 source, providing sensing and current limiting for the
circuit). The monitoring at low side is stopped if a short circuit to ground at the high side (main relay 1) is detected or it
is switched off for some reason. Failure detection of is only possible if the low side power stage is switched off. With
report of 'short circuit to ground' (on the low side of the metering unit) longer than 0.28 seconds and the power stage
has most likely switched off.
Cause:
Fuel high pressure pump circuit is shorted to a low source.
1. Faulty fuel high pressure pump control circuit, shorted to a low source.
Solution:

2. Disconnect the Engine Injector harness from the ECU at connector 3. Use a multi-meter to test for continuity
from the Engine Injector harness side of connector 3, pin 10 to ground. There should be no continuity.
A. If there is continuity, continue with step 3
B. If there is no continuity, try reloading the ECU software and if the error reoccurs, replace the ECU.
3. Disconnect the Engine Injector harness from the Fuel high pressure pump at connector ZME and use a multi-
meter to check for continuity on the fuel high pressure pump side of connector ZME, pins 1 and 2 to chassis
ground. There should be no continuity on either pin to ground.
A. If there is continuity on either pin, the fuel high pressure pump solenoid coil has failed, replace the solenoid.
B. If there is no continuity on either pin, there is a short to low source in the Engine Injector harness, locate
and repair the short to ground.
has been resolved.
ation.
47365539 08/07/2012
55.DTC / 791
3138-Metering Unit - Temperature Too High

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Context:
The engine control unit has determined that a short circuit condition exists in the fuel high pressure pump circuit. The
metering unit of the fuel high pressure pump regulates the pressure in the common rail. The metering unit is controlled
by both main relay 1 high side and a low side power stages (Main Relay 1 is an electronic control circuit within the
ECU used to provide fixed and variable control signals to devices external to the ECU. The monitoring at low side is
stopped if a short circuit to ground at the high side (main relay 1) is detected or it is switched off for some reason.
Failure detection of an over current condition is only possible if the low side power stage is switched on and the open
circuit condition only if it is switched off. With the current settings, the monitoring is shut off during after-run. This
error is the result of the power stage hardware report of 'excess temperature' (high current) in the metering unit circuit
longer than 200 milliseconds.
Cause:
Fuel high pressure pump circuit is shorted.
1. Faulty fuel high pressure pump, shorted solenoid coil.

2. Faulty control circuit, short circuit.
Solution:
1. Disconnect the Engine Injector harness from the ECU at connector 3. Use a multi-meter to check the resistance
on the Engine Injector harness side of connector 3, from pin 9 to pin 10. There should be approximately 3.2 Ω.
A. If there is approximately 3.2 Ω, use EST to check for other ECU errors that could inhibit operation of the
ECU main relay 1 circuit and follow those troubleshooting procedures.
B. If there is significantly less than 3.2 Ω, leave connector 3 disconnected and continue with step 2.
2. Disconnect the Engine Injector harness from the fuel high pressure pump at connector ZME. Use a multi-meter
to check the resistance of the fuel high pressure pump solenoid coil. There should be approximately 3.2 Ω.
A. If there is approximately 3.2 Ω, leave connector ZME disconnected and continue with step 3.
B. If there is significantly less than 3.2 Ω, replace the fuel high pressure pump solenoid coil.
Engine Injector harness side of connector 3, pin 9. There should not be continuity.
A. If there is no continuity, leave the connectors disconnected and continue with step 4.
B. If there is continuity, the fuel high pressure pump control circuit wires have been shorted together, locate
and repair the shorted wires.
Engine Injector harness side of connector 3, pin 10. There should not be continuity.
A. If there is no continuity, try reloading the ECU software and if the error reoccurs, replace the ECU.
B. If there is continuity, the fuel high pressure pump control circuit wires have been shorted together, locate
and repair the shorted wires.
47365539 08/07/2012
55.DTC / 792
3142-High Pressure Test - Test Active

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Context:
The engine control unit (ECU) has acknowledged that the 'High Pressure Test' is running. The 'High Pressure Test' is
a test procedure used to evaluate the performance of the fuel high pressure unit (pump, rail pressure control valve,
etc.) and is executed via a diagnostic tester request. If this test is running the rail pressure monitoring has to be
deactivated, which is done by setting this fault path. Therefore, this failure path is used more for information purposes
and inhibit handling than as an actual error status.
47365539 08/07/2012
55.DTC / 793
3145-Terminal 15 - No Signal
580N T4, 580SN T4, 580SN WT T4, 590SN T4

NOTICE: Fault Code 3145 is stored historical information. For multiple occurrences of this fault proceed with the
following tests.
Cause:

Solution:
rence.

2. Check voltage at ECU (Engine Control Unit).
(1) Disconnect ECU connector X-461. Inspect pins, wiring and connectors for damage, abrasion, corrosion or
incorrect attachment.
(2) Turn ignition switch to the ON position. measure the voltage from ECU connector X-461, pin 54 to chassis
ground. The voltage should be approximately 12 V.
good go to Step 3.
B. OK – There is not a problem at this time. Return to Step 1 to confirm elimination of the fault.
3. Check supply voltage to ignition switch.
(1) Turn ignition switch to the OFF position. Disconnect the ignition switch connector. Inspect pins, wiring and
connectors for damage, abrasion, corrosion or incorrect attachment.
47365539 08/07/2012
55.DTC / 794
(2) Measure the voltage from pin 1 of the ignition switch connector to ground. The voltage should be approxi-
mately 12 V. If no voltage is present check fuse F-025.
A. NOT OK – Determine break in circuit and repair. Return to Step 1 to confirm elimination of fault.
4. Check ignition switch.
(1) Measure the resistance from ignition switch pin 1 to pin 4. The resistance should greater than 20,000 ohms.
Wiggle the harness during measurement to revel an intermittent condition.
(2) Turn ignition switch to the ON position (with the ignition switch connector removed). Measure the resistance
between ignition switch from pin 1 to pin 4 on switch. The resistance should be less than 10 ohms.
A. NOT OK – Replace ignition switch. Return to Step 1.
5. Check circuit
RCPH10TLB302AAF 3
(1) Fuse block

(2) Diagnostic connector
(1) Disconnect fuse block and inspect connections and wiring for damage, abrasion, corrosion or incorrect at-
tachment.
A. NOT OK – Circuit is open. Repair or replace harness as required. Go to Step 1.
(1) Remove and replace ECU.
for assistance.
47365539 08/07/2012
55.DTC / 795
3177-Engine Overspeed Detected

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Context:
The Engine Control Unit (ECU) has detected an engine over-speed condition. An engine over-speed can occur both
during certain engine operating conditions without any defect in a component, for example downhill driving, or as a
result of, for example another ECU error. This error is for information purposes and is initiated by engine speed in
excess of 2800 RPM for over 5 seconds and is reset once the engine speed is below the threshold for over 2 seconds.
Though this error by itself does not require any action, the over-speed state can cause an injection shutoff request
within the ECU. If this error reoccurs frequently, check driving conditions of the vehicle, engine speed acquisition and
injection system for quantity set-point and actual value during fault recognition, check also for other ECU errors.
47365539 08/07/2012
55.DTC / 796
3239-Engine Controller EEPROM - Read Operation Error

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Context:
The engine control unit (ECU) has detected an error during the last EEPROM read operation. The hardware encap-
or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management (DSM) and
depending on their value a failure or no failure is detected. If a failure is detected this error sets and should reset
immediately if the EEPROM operates correctly. This failure can be the result of wrong programming / flashing of the
ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the
ECU.
47365539 08/07/2012
55.DTC / 797
3240-Engine Controller EEPROM - Write Operation Failure

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Context:
The engine control unit (ECU) has detected an error during the last EEPROM write operation. The hardware encap-
or not found. These flags are processed every 20 milliseconds by the Diagnostic System Management (DSM) and
depending on their value a failure or no failure is detected. If a failure is detected this error sets and should reset
immediately if the EEPROM operates correctly. This failure can be the result of wrong programming / flashing of the
ECU or an internal defect. Try to flash the ECU correctly with the proper data set. If the error persists, replace the
ECU.
47365539 08/07/2012
55.DTC / 798
3241-Engine Controller EEPROM - Default Value Used

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Context:
The engine control unit (ECU) has detected that substitute values for the EEPROM values are used. This happens if a
checksum error (CRC) is registered during reading. The hardware encapsulation of the ECU checks each data block
of the EEPROM and sets a status flag depending on if an error is found or not found. These flags are processed every
20 milliseconds by the Diagnostic System Management (DSM) and depending on their value a failure or no failure
is detected. If a failure is detected this error sets and should reset immediately if the EEPROM operates correctly.
This failure can be the result of wrong programming / flashing of the ECU or an internal defect. Try to flash the ECU
correctly with the proper data set. If the error persists, replace the ECU.
47365539 08/07/2012
55.DTC / 799
3249-TPU Monitoring - Time Deviation Between TPU And System

Not Plausible
580N T4, 580SN T4, 580SN WT T4, 590SN T4

Context:
The engine control unit (ECU) has detected that the TPU (time processing unit) and CPU (central processing unit)
have operated outside the established parameters more than 4 times since last ECU recovery (initialization). As
the time base of the CPU is checked according to a query / response communication with the monitoring module
(watchdog) it should be correct if no error has been detected and therefore can be used to check the time base of the
TPU. For this purpose the time basis of the TPU and CPU are compared every 10 ms. After 100 ms the maximum and
the minimum value together with the absolute value of the sum of the time differences are evaluated. If the maximum
time difference between the TPU and CPU time base exceeds the threshold of 81 ms or the minimum time difference
is below the limit of 81 ms or the absolute value of the sum of the time differences is above 81 msan error counter
is incremented. If this counter exceeds the value of 4, this fault is set and initiates an ECU recovery (reset). If this
failure persists, the ECU will need to be replaced.
47365539 08/07/2012
55.DTC / 800
3250-Dataset - Variant Defect

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Cause:
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 801
3251-Dataset - Requested Variant Could Not Be Set

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Cause:
Solution:
rence.

for assistance.
47365539 08/07/2012
55.DTC / 802
3316-Minimum Number Of Injections Not Reached - Stop Engine

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Context:
The engine control unit (ECU) has determined that the minimum number of injections was not reached. The injector
shutoff function (within the ECU) can switch off a single injector valve or an entire injection bank if a defect has been
detected in a component (monitoring is performed in other fault paths). The shutoff procedure is performed either for
an individual cylinder or for an entire bank. However, if too many cylinders are shut down by the shutoff function it is
no longer possible to run the engine securely and it has to be shut down entirely. In this case the fault path at hand
is set. It is possible for the engine to continue running on two cylinders. The test frequency is once per injection.
If this error occurs, see individual injector and injection-bank errors which have triggered the shutoff or error in the
component.
47365539 08/07/2012
55.DTC / 803
3358-CAN transmit timeout

580N T4, 580SN T4, 580SN WT T4, 590SN T4

Context:
Cause:

4. Faulty ECU
Solution:
last occurrence.
an indication of an intermittent connection in the CAN circuit. Check all wire and connector to verify they are
RCPH11TLB007FAL 1
47365539 08/07/2012
55.DTC / 804
machine service.
RCPH11TLB034GAL 2
47365539 08/07/2012
55.DTC / 805
CAN Low X-029 pin 3
CAN Low X-498 pin D


nector pin D)
47365539 08/07/2012
55.DTC / 806
RCPH11TLB074FAL 3
CAN Low X-029 pin 3
CAN Low X-498 pin D
47365539 08/07/2012
55.DTC / 807
RCPH11TLB072FAL 4
CAN Low X-029 pin 3
CAN Low X-498 pin D
47365539 08/07/2012
55.DTC / 808
Index
FAULT CODES - DTC

0000-Retrieving fault codes, Backhoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1001-Engine Air Filter Blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1002-Engine coolant temperature too high, critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1003-Air conditioning pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1004-Hydraulic filter blocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1009-Transmission oil temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1010-Foot throttle signal out of range, IVS not changing state in 300 ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1011-Foot throttle signal out of range, throttle above 95% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1012-Foot throttle signal out of range, throttle below 5% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1013-Foot throttle signal out of range, signal unusable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1014-Battery charge voltage too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1015-Battery charge voltage too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1018-Boost air temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1019-Engine coolant temperature too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1020-Transmission oil temperature above normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1021-Fuel temperature above normal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1022-Water in fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1023-Foot throttle supply voltage too high, over 5.2 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1024-Foot throttle supply voltage too low, under 4.8 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1025-Foot throttle sensor voltage over 5.3 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1026-Foot throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1032-Hand throttle supply voltage too low, under 4.8 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
580N Power Shuttle, 580N T4, 580SN Power Shuttle, 580SN T4, 580SN WT Power Shuttle, 580SN WT T4, 590SN Power Shuttle,
590SN T4
1033-Hand throttle sensor voltage over 5.3 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
590SN T4
1034-Hand throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1035-Hand throttle sensor signal above 95% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
590SN T4
1036-Hand throttle sensor signal below 5% of input for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
590SN T4
1037-Hand throttle sensor out of range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
590SN T4
1039-Hand throttle sensor voltage under 200 mV for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
590SN T4
1040-Engine RPM over 2750 for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 809
1041-Engine RPM over 3000 for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1044-Fuel level sensor below 2.0 ohm for 5 seconds, shorted low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1045-Fuel level sensor open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1047-Transmission temperature sensor below 3.0 ohms for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1050-Alternator L+ terminal under 1.5 volts for 5 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
580N T4, 580SN T4, 580SN WT T4, 590SN T4
1051-1059- Timeout of CAN message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3006-Coolant Temperature Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3007-Coolant Temperature Signal - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3008-Coolant Temperature Signal - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3010-Air intake temperature sensor signal above maximum range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3011-Air intake temperature sensor signal below minimum range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3015-Fuel Temperature Sensor - Signal Above Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3016-Fuel Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3019-Boost Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3022-Boost Pressure Sensor - Signal Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3023-Atmospheric pressure sensor - signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3024-Atmospheric Pressure Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3025-Atmospheric pressure sensor - signal below range minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3028-Oil Pressure Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3029-Oil Pressure Sensor - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3030-Oil Pressure Sensor - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3031-Oil Pressure Sensor - Hardware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3032-Oil Pressure Sensor - Value Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3033-Oil Temperature Sensor - Signal Not Plausible (Compared With Coolant Temperature) . . . . . . . . . . . . . . . 157
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3034-Oil Temperature Sensor - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3035-Oil Temperature Sensor - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3037-Boost Pressure Sensor - Signal Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3047-Main Relay Failure - Short Circuit To Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 787
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3048-Main Relay Failure - Short Circuit to Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 789
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3051-Battery Voltage To Engine Controller - Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3052-Battery Voltage To Engine Controller - Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3059-ECM afterrun was interrupted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3060-Cylinder 1 - Unclassifiable Error In Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
3061-Cylinder 1 - Injector Cable Short Circuit (Low Side To Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3062-Cylinder 1 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
3063-Cylinder 1 - Injector Cable Short Circuit (High Side To Ground) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3070-Cylinder 3 - Electronic injector , Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
47365539 08/07/2012
55.DTC / 810
3078-Cylinder 2 - Electronic injector, Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3082-Cylinder 4 - Electronic injector, Low signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
3088-Crankshaft sensor lost synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3089-Crankshaft Sensor - Invalid Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3090-Phase defect of camshaft speed sensor signal detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3091-Camshaft sensor phase synchronization failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3093-Offset Between Camshaft And Crankshaft - Outside Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3095-Operating With Camshaft Sensor Only - Backup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3096-CAN Bus: Bus Off error CAN A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3102-Rail Pressure Sensor CP3 - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3104-Rail Pressure Relief Valve - Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3105-Rail Pressure Relief Valve - Pressure Shock Requested . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3106-Rail Pressure Relief Valve - Did Not Open After Pressure Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3107-Metering unit output short circuit to battery on low side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3108-Fuel Metering Unit - Short Circuit To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 791
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3110-Rail Pressure Sensor Monitoring - Signal Above Range Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3111-Rail Pressure Sensor Monitoring - Signal Below Range Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3112-Rail Pressure Sensor CP3 - Signal Above Maximum Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3118-ECM 12V sensor supply voltage high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3119-ECM 12V sensor supply voltage low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3137-Metering Unit - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3138-Metering Unit - Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 792
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3139-Metering Unit Signal Range Check - Signal Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3140-Metering Unit Signal Range Check - Signal Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3141-Set point of fuel volume flow through metering unit is lower than calculated limit . . . . . . . . . . . . . . . . . . . . . 240
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3142-High Pressure Test - Test Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 793
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3145-Terminal 15 - No Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 794
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3146-Water detected in fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3147-Oil Temperature Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3171-Fuel rail system pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3172-Fuel rail system pressure too high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3173-Rail Pressure Governor Deviation Below Min. Limit for Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 811
3174-Rail Pressure Governor Deviation Exceeded Max. Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3175-Fuel system leak detected - large leak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3176-Fuel delivery exceeded threshold for pressure in overrun mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3177-Engine Overspeed Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 796
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3188-Cylinder 1 Warning - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
3192-Cylinder 2 - Open Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
3210-Bank 1 - General Short Circuit To Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
3211-Bank 1 - Injector cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
3213-Bank 1 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
3218-Bank 2 - General Short Circuit On Injector Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
3219-Bank 2 - Injector Cable Short Circuit Low Side To Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
3221-Bank 2 - Unclassifiable Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
3227-Injection Processor Error - Internal Reset/Clock Loss/Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3228-Injection Processor Error - Unlocked/Initialization Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3229-Injection processor error - stop engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3235-Number of Injections Limited - by Charge Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3236-Number of Injections Limited - by Quantity Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3237-Number of Injections Limited - by Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3238-Communication error of CJ940 processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3239-Engine Controller EEPROM - Read Operation Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 797
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3240-Engine Controller EEPROM - Write Operation Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 798
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3241-Engine Controller EEPROM - Default Value Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 799
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3242-Engine Controller (Locked) Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3243-Engine Controller Recovery (Suppressed) - Recovery Occurred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3244-Soft Controller Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3245-Engine Controller - Watchdog Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3246-Shutoff Paths During Initialization - Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3247-Shutoff Paths Failed During Initialization - Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3248-Shutoff Paths During Initialization - Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3249-TPU Monitoring - Time Deviation Between TPU And System Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . 800
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3250-Dataset - Variant Defect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 801
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3251-Dataset - Requested Variant Could Not Be Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 802
580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 812
3252-Controller Watchdog - SPI Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3253-ADC Monitoring - Reference Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3254-ADC Monitoring - Reference Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3255-ADC Monitoring Test Impulse Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3256-ADC Monitoring Queue Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3258-HS power stage hardware reports 'short circuit to battery' longer than 500 ms. . . . . . . . . . . . . . . . . . . . . . . 296
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3259-HS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . . . . . . . . . 298
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3260-LS power stage hardware reports 'open load' longer than 100 ms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3261-LS power stage hardware reports 'short circuit to battery' or 'excess temperature' longer than 100 ms. . 301
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3262-LS power stage hardware reports 'short circuit to ground' longer than 100 ms. . . . . . . . . . . . . . . . . . . . . . . 303
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3263-Busoff in CAN C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3265-Energizing time exceeds limit of over run monitoring, injection time too long . . . . . . . . . . . . . . . . . . . . . . . . 306
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3266-Error in engine speed check, speed signal not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3278-Engine Controller Supply Voltage Too High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3279-Engine Controller Internal Supply Voltage Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3280-Sensor Supply Voltage 1 - High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3281-Sensor Supply Voltage 1 - Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3293-Fuel Metering Unit: maximum positive deviation of rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . 324
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3301-Fuel high pressure pump is at minimum delivery and the Rail pressure is not reducing . . . . . . . . . . . . . . . 325
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3305-Cannot maintain rail pressure above the minimum pressure of 200 Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3309-Maximum Fuel rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3316-Minimum Number Of Injections Not Reached - Stop Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 803
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3334-Timeout of CAN Message TSC1 Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3339-Timeout of CAN Message TSC1 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3358-CAN transmit timeout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 804
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3361-ECM EEPROM - General Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3362-Torque to Quantity Map - Not Plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3363-Atmospheric Pressure Sensor - Processed via ADC, not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3368-Torque limitation due to performance limiter, may be triggered by inducament . . . . . . . . . . . . . . . . . . . . . . . 337
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3369-Torque limitation due to smoke limitation has been active for 120 seconds . . . . . . . . . . . . . . . . . . . . . . . . . . 338
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3370-Torque limitation due to engine protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3371-Torque limitation due to Fuel quantity Limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3374-Unit injector NEMA codes are invalid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3402-Rail pressure sensor: maximum rail pressure exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3405-ECU Power stages: Open load temperature error on the Turbocharger PWM output power stage . . . . . . 343
580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 813
3406-ECU Power stages: Over temperature error on the Turbocharger PWM output power stage . . . . . . . . . . . 346
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3408-Lambda sensor: Oxygen concentration implausibly high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3409-Oil pressure too low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3410-Permanent governor deviation for valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3414-3417-Short circuit in glow plug wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3420-CAN Bus Received frames: DFC of Auxiliary Engine Shutdown Switch Message . . . . . . . . . . . . . . . . . . . . 361
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3425-Turbocharger: Over boost deviation at P2 too high in pressure charger regulator . . . . . . . . . . . . . . . . . . . . 362
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3426-Low efficiency in DPF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3517-Atmospheric Temperature Sensor signal range check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3518-Atmospheric Temperature Sensor signal range check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3616-Torque limitation due to turbo charger protection high altitude operation related . . . . . . . . . . . . . . . . . . . . . 366
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3648-EVGT Boost pressure monitoring for over boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3650-Battery voltage: SRC high for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3651-Battery voltage: SRC low for battery voltage sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3652-CAN Bus: Bus off of CAN node A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3655-Torque limitation, Engine protection: General report of the event of torque limitations . . . . . . . . . . . . . . . . 375
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3656-Torque limitation, Engine protection: Torque limitation caused by particulate filter . . . . . . . . . . . . . . . . . . . . 376
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3663-EGR command saturation over higher threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3664-EGR command saturation over lower threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3667-Open load error for power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3668-Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3669-Short circuit to battery on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3671-Short circuit to ground on Out1 error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3673-Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3674-Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3675 -DFC for long time valve drift at closed position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3676-DFC for valve position sensor voltage SRC high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3677-DFC for valve position sensor voltage SRC low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3680-Injection cut off: Injection cut off demand (ICO) for shut off coordinator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3688-Water sensor in the fuel filter: WIF sensor check is failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3689-Faulty diagnostic data transmission or protocol error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3690-DFC for glow module error in GCU-T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3691-No load error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3692-Over temperature error on ECU power stage for glow plug low voltage system . . . . . . . . . . . . . . . . . . . . . . 427
580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 814
3693-Short circuit to battery error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3694-Short circuit to ground error for low voltage system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3699-EEPROM: Error in EEPROM block EEPData1, SD correction can not be calculated . . . . . . . . . . . . . . . . . 435
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3702-Injection control: Detection of failed engine start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3703-Injection control: check of minimum rail pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3704-3706- Injector adjustment programming: check of missing injector adjustment value programming . . . . . 438
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3707-Lambda sensor: Open circuit at the lambda sensor Nernst cell pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3708-Lambda sensor: Open circuit at the lambda sensor pump current pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3709-Lambda sensor: Open circuit at the lambda sensor virtual ground pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3710-Lambda sensor: Fault to indicate dynamics of the sensor signal too small . . . . . . . . . . . . . . . . . . . . . . . . . . 445
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3711-SCB error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3712-Lambda sensor: SCG error of the LSU heater power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3713-Lambda sensor: Open Load error of the LSU Heater Power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3714-Lambda sensor: Fault code to indicate SRC High error for O2 calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 453
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3715-Lambda sensor: SRC Low error for O2 calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3720-Lambda sensor: Low battery voltage at the SPI chip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3721-Lambda sensor: Fault check to indicate SPI chip error of lambda sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 458
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3722-Lambda sensor: LSU sensor temperature Ri exceeds the maximum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3723-Lambda sensor: LSU sensor temperature Ri is below the minimum limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3724-Lambda sensor: Short to battery at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3725-Lambda sensor: Short to ground at IA, IP, UN, VG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3727-Low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3728-Too low oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3735-Fuel Metering Unit: over temperature of device driver of metering unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3736-O2 concentration is outside the predefined window during Heater coupling detection . . . . . . . . . . . . . . . . . 468
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3738-ECU Internal: Diagnostic fault check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3739-Power stages, Injector: Loss of synchronization sending bytes to the MM from CPU . . . . . . . . . . . . . . . . . 470
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3740-Power stages, Injector: DFC to set a torque limitation once an error is detected before MoCSOP's error re-
action is set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3741-Power stages, Injector: Wrong set response time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3743-Power stages, Injector : Diagnostic fault check to report the error in under voltage monitoring . . . . . . . . . 473
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3773-EVGT Turbocharger Control Underboost Pressure failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3786-Diesel particulate filter signal range check is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3787-Diesel particulate filter (DPF) : Signal range check flow resistance of the particulate filter - very high . . . 476
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3789-Regeneration duration exceeds maximum allowed duration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3790-Diesel particulate filter: Signal range check flow resistance of the particulate filter - max . . . . . . . . . . . . . . 478
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3794-Intake air pressure sensor: Plausibility check for air pressure at the upstream of intake valve sensor . . . 482
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3796-Diesel particulate filter pressure sensor hose line error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3797-Diesel particulate filter pressure sensor: SRC high for differential pressure sensor . . . . . . . . . . . . . . . . . . . 484
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3798-Diesel particulate filter pressure sensor: SRC low for differential pressure sensor . . . . . . . . . . . . . . . . . . . . 487
580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 815
3799-Rail system: Rail pressure reduction by blank shots during after run (BSA) aborted during post drive of ECU
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3800-Pressure relief valve: Quantity balance check if a successful PRV opening is ensured . . . . . . . . . . . . . . . 491
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3801-Turbine upstream pressure sensor: SRC high for turbine upstream pressure sensor . . . . . . . . . . . . . . . . . 492
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3802-Turbine upstream pressure sensor: SRC low for turbine upstream pressure sensor . . . . . . . . . . . . . . . . . . 495
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3803-ECU internal: Internal communication signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3808-Fuel Metering Unit: set point of metering unit in idle mode not plausible . . . . . . . . . . . . . . . . . . . . . . . . . . . . 499
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3810-Rail pressure raw value is intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3811-ECU sensor supply monitor : ECU internal: Error sensor supplies 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3812-Physical range check high for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3813-Physical range check low for ECU temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3814-ECU temperature sensor: SPI error ECU temperature sensor (LM71) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 507
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3815-Low efficiency in DPF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 508
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3818-Open load error for power stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 509
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3820-Over temperature error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3825-Short circuit over load error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3826-Temperature dependent over current error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3827-Under voltage error for H-bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3838-Oxidation catalyst upstream temperature shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 535
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3839-Oxidation catalyst upstream temperature shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3840-Diesel particulate filter upstream temperature sensor shorted to high source . . . . . . . . . . . . . . . . . . . . . . . . 541
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3841-Diesel particulate filter upstream temperature sensor shorted to low source . . . . . . . . . . . . . . . . . . . . . . . . . 544
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3844-3847-Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Max
value injector 1, 2, 3 or 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 547
3848-3851-Zero Fuel Calibration by Lambda (ZFL) : DFC reporting error state on comparing energizing time to Min
value injector 1, 2 3 or 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 548
3852-Lambda sensor: The maximum allowed time for blow out is exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3856-Coolant temperature signal test failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3899-Info: Engine temperature exceeded pre-warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3900-Info: Engine temperature exceeded warn level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3906-Injector: Number of injections is limited by quantity balance of high pressure pump . . . . . . . . . . . . . . . . . . 554
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3910-Fuel metering unit: Error check for loose contact between metering unit (MeUn) and ECU . . . . . . . . . . . . 555
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3915-Pressure Relief Valve: Averaged rail pressure is outside the expected range with open PRV . . . . . . . . . . 556
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3916-Pressure Relief Valve: Open time of PRV for wear out monitoring had exceeded maximum value . . . . . . 557
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3998-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 558
580N T4, 580SN T4, 580SN WT T4, 590SN T4
3999-Unknown error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 560
580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
55.DTC / 816
4000-Power supply (pin 2), forward FWD drive (pin 3), or RVS drive (pin 4) drive shorted to ground H-type and
S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562
4001-Power supply (pin 5), PWM 1 drive (pin 6), or PWM 2 drive (pin 7) drive shorted to ground H-type transmission
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 568
4002-Power supply for digital outputs (pin 8) does not have power H-type and S-type transmission . . . . . . . . . 573
4004-Battery voltage (Pin 34) voltage below 10 volts for 2.5 seconds with engine speed above 900 rpm H-type and
4005-Downshift delayed due to possible engine overspeed condition H-type and S-Type transmission . . . . . . 581
4006-FWD input (Pin 12) feedback circuit is reading current with command H-type and S-type transmission . 582
4007-FWD input (Pin 12) current is too low with command present H-type and S-type transmission . . . . . . . . . 585
4008-FWD solenoid is drawing more current than commanded H-type and S-type transmission . . . . . . . . . . . . 588
4009-FWD solenoid is drawing less current than commanded H-type and S-type transmission . . . . . . . . . . . . . 591
4011-RVS input (pin 40) feedback circuit is reading current with command H-type and S-type transmission . . 594
4012-RVS input (pin 40) current is too low with command present H-type and S-type transmission . . . . . . . . . . 597
4013-RVS solenoid is drawing more current than commanded H-type and S-type transmission . . . . . . . . . . . . . 600
4014-RVS solenoid is drawing less current than commanded H-type and S-type transmission . . . . . . . . . . . . . . 603
4016-First and third shift modulation solenoid input (pin 13) feedback circuit is reading current without command
H-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606
4017-First and third shift modulation solenoid input (pin 13) current is too low with command present H-type trans-
mission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609
4018-First and third shift modulation solenoid is drawing more current than commanded H-type transmission 612
4019-First and third shift modulation solenoid is drawing less current than commanded H-type transmission . 615
4021-Second and fourth shift modulation solenoid input (pin 41) feedback circuit is reading current with command
H-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
4022-Second and fourth shift modulation solenoid input (pin 41) current is too low with command present H-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 621
4023-Second and fourth shift modulation solenoid is drawing more current than commanded H-type transmission
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624
4024-Second and fourth shift modulation solenoid is drawing less current than commanded H-type transmission
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627
4026-First / Third shift solenoid shorted to ground H-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 630
4027-Second / Fourth shift solenoid shorted to ground H-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 633
4028-Differential lock or 4 wheel drive solenoid shorted to ground H-type and S-type transmission . . . . . . . . . . 636
4029-Shifter Lever improperly connected, no power to pin 16, pin 18, or pin 46 for more than 3 seconds H-type and
4030-Shifter Lever malfunction: transmission in neutral receives forward and neutral together H-type and S-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643
4031-Shifter Lever malfunction: transmission in neutral receives reverse and neutral together H-type and S-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648
4032-Shifter Lever malfunction: transmission in forward receives forward and reverse together H-type and S-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
4033-Shifter Lever malfunction: transmission in reverse receives forward and reverse together H-type and S-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 658
4034-Shifter Lever malfunction: transmission in forward receives neutral and forward together H-type and S-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 663
47365539 08/07/2012
55.DTC / 817
4035-Shifter Lever malfunction: transmission in reverse receives neutral and reverse together H-type and S-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668
4036-During transition from second to third gear, and Gear CMD_01 signal erratic or incorrect H-type and S-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 673
4037-During transition from first to second gear, and Gear CMD_02 signal erratic or incorrect H-type and S-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 678
4038-During transition from third to fourth gear, and Gear CMD_02 signal erratic or incorrect H-type and S-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 683
4040-Transmission Controller Driveline Configuration H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . 688
4041-Transmission output shaft frequency above 3000 Hz detected H-type and S-type transmission . . . . . . . . 689
4042-Temperature signal erratic or incorrect H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692
4043-Temperature sensor input (Pin 43) is shorted to a ground H-type and S-type transmission . . . . . . . . . . . . 695
4044-Temperature sensor input (Pin 43) is open circuit or shorted to a voltage above 5 volts H-type and S-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 698
4045-Charge pressure is not detected when engine speed is above 700 rpm for 10 seconds H-type and S-type
transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 701
4046-Charge pressure is not detected and vehicle speed is over 10 kph (6 mph) H-ype and S-type transmission
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704
4047-Charge pressure switch is closed with no frequency input to the TRAX controller H-type and S-type transmis-
sion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 707
4054-Unknown vehicle model value from VCM S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 710
4100-Missing EEC 1 message on CAN H-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711
4101-Internal TRAX failure, hardware measurement H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . . 715
4102-Internal TRAX failure, software timing H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 716
4103-Internal TRAX failure, software not running H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . 717
4105-Internal TRAX failure, redundant flash memory H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . 718
4106-Internal TRAX failure, sensor supply high H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 719
4107-Internal TRAX failure, sensor supply low H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 723
4200-First shift solenoid shorted to ground S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 727
4203-Fourth shift solenoid shorted to ground S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 730
4204-System detects different gear than commanded S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 733
4205-System can not engage required gear. (Engaged gear is different than requested gear) S-type transmission
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 740
4206-Gear engagement failed S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 742
4207-1ST/2ND gear shift rail position reporting first gear at startup S-type transmission . . . . . . . . . . . . . . . . . . . 744
4208-1ST/2ND gear shift rail position reporting second gear at startup S-type transmission . . . . . . . . . . . . . . . . 746
4209-3RD/4TH gear shift rail position reporting third gear at startup S-type transmission . . . . . . . . . . . . . . . . . . . 748
4210-3RD/4TH gear shift rail position reporting forth gear at startup S-type transmission . . . . . . . . . . . . . . . . . . 750
4211-First and second gear sensor input shorted to ground S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 752
4212-First and second gear sensor input voltage too high S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 755
4213-Third and forth gear sensor input shorted to ground S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 758
4214-Third and forth gear sensor input voltage too high S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761
4825-Loss of TC1 message after 15 seconds H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . 764
47365539 08/07/2012
55.DTC / 818
4850-Possible detection wrong transmission type for installed software H-type and S-type transmission . . . . . 765
4995-Incorrect VCM configuration of transmission type H-type and S-type transmission . . . . . . . . . . . . . . . . . . . 766
4996-Electronic transmission offline or incorrect VCM configuration of transmission type H-type and S-type trans-
mission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 767
4997-Loss of messaging from Trax controller H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . 768
4998-Unknown transmission error code with amber lamp H-type and S-type transmission . . . . . . . . . . . . . . . . . 773
4999-Unknown transmission error code with red lamp H-type and S-type transmission . . . . . . . . . . . . . . . . . . . . 774
9001-Hour meter plausibility, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 775
580N T4, 580SN T4, 580SN WT T4, 590SN T4
9002-Hour meter RAM checksum failure, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 776
580N T4, 580SN T4, 580SN WT T4, 590SN T4
9003-J1939 receive buffer overflow, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 777
580N T4, 580SN T4, 580SN WT T4, 590SN T4
9004-EEPROM checksum failure, hour meter location 1, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 778
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
580N T4, 580SN T4, 580SN WT T4, 590SN T4
9007-Abnormal reset watchdog time-out, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 781
580N T4, 580SN T4, 580SN WT T4, 590SN T4
9008-A/D fault foot throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 782
580N T4, 580SN T4, 580SN WT T4, 590SN T4
9009-A/D fault foot throttle power, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 783
580N T4, 580SN T4, 580SN WT T4, 590SN T4
9010-A/D fault hand throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784
580N T4, 580SN T4, 580SN WT T4, 590SN T4
9011-A/D fault foot throttle, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 785
580N T4, 580SN T4, 580SN WT T4, 590SN T4
9012-A/D fault, internal error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 786
580N T4, 580SN T4, 580SN WT T4, 590SN T4
47365539 08/07/2012
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PRINTED IN U.S.A.
47365539 08/07/2012
EN
SERVICE MANUAL
Front loader and bucket
580N NA
580SN WT NA
580SN NA
590SN NA
47365539 08/07/2012
82
Contents
Front loader and bucket - 82
Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.100
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.300
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82
Arm - 100
580N NA
580SN WT NA
580SN NA
590SN NA
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82.100 / 1
Contents
Arm - 100
FUNCTIONAL DATA
Arm
Exploded view - Loader frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Exploded view - Bucket frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Exploded view - Lift cylinder hydraulic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE
Arm
Remove - Loader frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install - Loader frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Remove Loader Clam Shell Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Install Loader Clam Shell Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Front loader and bucket - Arm
Arm - Exploded view - Loader frame

RCPH10TLB043GAL 1
Loader frame
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Arm - Exploded view - Bucket frame

RCPH10TLB041GAL 1
Bucket frame
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Arm - Exploded view - Lift cylinder hydraulic installation

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RCPH10TLB004HAL 1
Lift cylinder hydraulic installation
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Arm - Remove - Loader frame

1. Raise the loader frame until the pivot pins for the
piston rod eyes of the lift cylinders are above the
hood. Stop the engine.
2. Fasten suitable lifting equipment to the loader frame
to hold the loader frame in place.
3. Remove the outer snap ring that holds the pivot pins
for the piston rod eyes of the lift cylinders.
4. Use suitable drivers and drive the pivot pins out of
the loader frame. Do not remove the drivers at this
time.
5. Disconnect the lifting equipment and lower the
6. Hold the right lift cylinder and remove the driver.
Lower the lift cylinder onto the front axle.
7. Hold the left lift cylinder and remove the driver. Lower
the lift cylinder and strut onto the front axle.
8. Move the loader control lever to the right or left to
relieve any pressure in the bucket circuit.
9. Disconnect the bucket cylinder hoses from the tubes
on the right side of the machine chassis upright. Fas-
ten an identification tag to each tube.
10. Install a cap on each hose and a plug in each tube.
Thread size is 7/8-14.
11. If equipped, disconnect the clam cylinder hoses from
the tubes on the left side of the machine chassis up-
right. Fasten an identification tag on each tube.
12. Install a cap on each hose and a plug in each tube.
Thread size is 7/8-14.
13. Remove both retaining bolts for the return-to-dig
switch mounting bracket. It is not necessary to
disconnect the return-to-dig switch wiring.
14. Disconnect the antirollback rod from the right bucket
cylinder link.
15. Disconnect the antirollback rod from the self-leveling
cam. Put the antirollback rod out of the way.
16. Remove the snap ring and the two hardened flat
washers from the right end of the loader lift frame
pivot shaft.
17. Fasten suitable lifting equipment to the loader frame
to hold the loader frame in place.
18. Use a suitable driver and drive the pivot shaft out of
the loader frame.
19. A wave washer and the self-leveling cam are located
between the loader frame and the machine chassis
upright. Raise the loader frame and remove these
parts.
20. Carefully move the machine out of the loader frame.
Next operation:
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Bucket - Install (84.100)
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Arm - Install - Loader frame

Prior operation:
Bucket - Remove (84.100)
1. Carefully move the machine into the loader frame.

2. Lower the loader frame into alignment with the ma-
chine chassis upright.
NOTE: It may be necessary to spread the loader arms to
position them over the pivot tube in the chassis uprights.
Use caution. Do not over spread the loader frame arms.
3. Install the wave washer (2)and self-leveling cam (1)
between the machine chassis upright and the loader
frame as shown.
RCPH10TLB934ABL 1
4. Start the pivot shaft into the loader frame from the left
side of the machine chassis upright.
5. Drive the pivot all the way through into the right
loader frame.
6. Install the two flat hardened washers and the snap
ring.
7. Install the antirollback rod. Make the connection at
the right bucket cylinder link as well as at the self-
leveling cam.
8. Install the return-to-dig switch mounting bracket us-
ing the 10 x 15 mm hex flange bolts. Torque to 26 -
31 N·m (19 - 23 lb ft).
9. Replace any tie straps required to hold wiring har-
ness in place.
10. Connect the bucket cylinder hoses with the appro-
priate tubes on the right side of the machine chassis
upright.
11. If equipped, connect the clam cylinder hoses with
the appropriate tubes on the left side of the machine
chassis upright.
12. Move the loader control lever to the float position.
13. Raise the left loader lift cylinder and strut. Posi-
tion the pivot pin in the loader frame bore and drive
through the strut and cylinder piston rod eye.
15. Connect the right loader lift cylinder in the same man-
ner as the left lift cylinder. Install the snap ring.
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16. Lubricate the pivot pins for the piston rod eyes of the
lift cylinders and the pivot shaft.
17. With the engine running at low idle, extend and re-
tract all loader cylinders three times to remove any
air from the circuits.
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Arm - Remove Loader Clam Shell Bucket

WARNING
Escaping fluid!
doctor immediately.
W0178A
1. Turn the power off. Activate the hydraulic controls to

relieve pressure in the system.
RCPH11TLB151AAM 1
2. Disconnect and cap hydraulic tubes.
RCPH11TLB152AAM 2
3. Remove pivot arm to bucket snap rings and pins.
4. Remove lift arm to bucket snap rings and pins.
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5. Remove bucket.
RCPH11TLB157AAM 7
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Arm - Install Loader Clam Shell Bucket

WARNING
Escaping fluid!
doctor immediately.
W0178A
1. Move the bucket into place.
RCPH11TLB157AAM 1
2. Install the lift arm to bucket snap rings and pins.
3. Install the pivot arm to bucket snap rings and pins.
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4. Remove the caps from the hydraulic lines. Recon-

nect the hydraulic lines.
RCPH11TLB151AAM 6
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Index
Arm - 100
Arm - Exploded view - Bucket frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Arm - Exploded view - Lift cylinder hydraulic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Arm - Exploded view - Loader frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Arm - Install - Loader frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Arm - Install Loader Clam Shell Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Arm - Remove - Loader frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Arm - Remove Loader Clam Shell Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Bucket - 300
580N NA
580SN WT NA
580SN NA
590SN NA
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82.300 / 1
Contents
Bucket - 300
TECHNICAL DATA
Bucket
General specification - Weld specifications for standard bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUNCTIONAL DATA
Bucket
Exploded view - Adjustment for return to dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view - Antirollback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Exploded view - Loader lift bucket control - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Exploded view - Loader lift bucket control - N and SN machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Exploded view - Bucket cylinder hydraulic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Exploded view - Clam cylinder circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Exploded view - Clam cylinder hydraulic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Exploded view - Antirollback linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SERVICE
Bucket
Adjust - Adjustment for return to dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adjust - Adjustment of antirollback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Replace - Replacement of weld on cutting edge for standard buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Replace - Replacement of bolt - on cutting edge for standard bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Replace - Replacement of bolt - on cutting edge for clam bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Replace - Replacement of tooth shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Replace - Replacement of tooth point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Front loader and bucket - Bucket
Bucket - General specification - Weld specifications for standard

bucket
1. 6 mm (0.25 in) Fillet

2. Fill groove
3. Fill corner
RCPH10TLB681AAL 1
RCPH10TLB682AAL 2
RCPH10TLB683AAL 3
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Bucket - Exploded view - Adjustment for return to dig

RCPH10TLB038GAL 1
1. Cap screw 3. Switch 5. Wave washer

2. Switch bracket 4. Cam
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Bucket - Exploded view - Antirollback

RCPH10TLB053GAL 1
1. Rollback cable 4. Cap screw 7. Snap ring

2. Nut 5. Washers 8. Rollback rod
3. Clevis 6. Bearing
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Bucket - Exploded view - Loader lift bucket control - 580SN-WT only

RCPH10TLB039GAL 1
1. Bolt 11. Cotter pin 21. Bellows

2. Nut 12. Pin 22. Clevis pin
3. Balljoint 13. Washer 23. Loader control valve
4. Washer 14. Bushing 24. Spacer
5. Handle shaft 15. U-bracket 25. Threaded insert
6. Two button handle (standard trans) 16. Bearing 26. 0-ring
7. Three button handle (powershift trans) 17. Bearing 27. Adjustable clevis
8. Boot 18. Shaft 28. Thin nut
9. Screw 19. Yoke linkage 29. Plug
10. Nut 20. Bucket control rod 30. Lift control rod
NOTE: Adjust length and offset of bucket control rod (20) and lift control rod (30) using clevis (27).
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Bucket - Exploded view - Loader lift bucket control - N and SN

machines
RCPH10TLB040GAL 1
1. Bolt 10. Nut 19. Yoke linkage

2. Washer 11. Cotter pin 20. Bucket control rod
3. Balljoint 12. Pin 21. Loader control valve
4. Nut 13. Washer 22. Spacer
5. Handle shaft 14. Bushing 23. Threaded insert
6. Two button handle (standard trans) 15. U-bracket 24. Pin
7. Three button handle (powershift 16. Bearing 25. Bellows
trans)
8. Boot 17. Bearing 26. Plug
9. Screw 18. Shaft 27. Lift control rod
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Bucket - Exploded view - Bucket cylinder hydraulic installation

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RCPH10TLB003HAL 1
Bucket cylinder hydraulic installation
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Bucket - Exploded view - Clam cylinder circuit

RCPH10TLB042GAL 1
Clam cylinder circuit
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Bucket - Exploded view - Clam cylinder hydraulic installation

RCPH10TLB047GAL 1
Clam cylinder hydraulic installation
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Bucket - Exploded view - Antirollback linkage

RCPH10TLB936ABL 1
Antirollback linkage
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Bucket - Adjust - Adjustment for return to dig


parking brake.
2. Lower the loader frame and put the bucket flat on the
floor or in the correct digging position.
3. Stop the engine.
4. Loosen the cap screws (1) and move the switch
bracket (2) and switch (3) until the roller on the
switch (3) touches the cam (4). Tighten the cap
screws (1). See the illustration Bucket - Exploded
view (84.100)
NOTE: Make sure the switch bracket is moved toward the inside of the machine so that the roller on the switch is fully
in contact with the cam.
5. Start the engine. Raise the loader frame all the way
and dump the bucket completely.
6. Increase the engine speed to full throttle.
7. Put the loader control lever in the rollback and then
the float position. The loader frame will lower to the
floor and the bucket will roll back.
8. Check the position of the bucket on the floor. When
the bucket reaches a level surface the lip should be
flat within 38 mm (1.5 in).
9. If the bucket is not in the correct position, do steps
11 through 14.
10. If the bucket is in the correct position, adjust the
pointer on the loader dump link to match the pointer
on the guide link.
11. Loosen the cap screws (1).
12. Move the switch bracket (2) and switch (1) forward if
the bucket did not roll back far enough.
13. Move the switch bracket (2) and switch (1) rearward
if the bucket rolled back too far.
14. Repeat steps 5 through 13 until the bucket returns to
the correct position.
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Bucket - Adjust - Adjustment of antirollback

1. Check to see that the cable assembly, which includes

the rollback cable (1), the nut (2), and the clevis (3), is
adjusted to a length of approximately 702 mm (27.64
in). See the illustration Bucket - Exploded view
(84.100).
2. Roll the bucket all the way back.
3. Raise the loader frame all the way.
4. Look at the side cutting edge of the bucket.
5. The side cutting edge must be approximately level.
6. If the side cutting edge is not in the specified position,
adjust the nut (2) and the clevis (3) on the rollback
cable (1) to change the length of the cable assembly.
Lengthen the cable assembly to increase the amount
of rollback. Shorten the cable assembly to decrease
the amount of rollback.
7. Use washers (5) as required to remove any space
between the bearings (6) and the snap rings (7) at
both ends of the rollback rod (8). If the washers are
not required, leave on rollback rod (8) between the
snap rings (7).
8. Tighten the cap screw (4) to 27 N·m (20 lb ft).
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Bucket - Replace - Replacement of weld on cutting edge for

standard buckets
1. If the bucket is not removed from the machine, raise

the bucket to a suitable height and use suitable sup-
ports to hold the loader frame and bucket in place.
2. If the bucket is equipped with bucket teeth, use car-
bon arc rod to remove the bucket teeth.
3. Use carbon arc rod or an acetylene cutting torch to
remove the welds that hold the cutting edge. Keep
distortion to a minimum when removing the cutting
edge.
4. When removing the bottom rear weld for the cutting
edge do not cut through the floor of the bucket.
1. Long lipped bucket weld
RCPH10TLB681AAL 1
5. Use a grinder to remove any welds or extra metal on

the bucket that will prevent the new cutting edge from
fitting correctly.
6. Put the cutting edge in place and use C-clamps to
hold the cutting edge in place. See the illustration for
the correct position of the cutting edge.
1. Long lip bucket 688 mm (27 in)
RCPH10TLB935ABL 2
7. Use E-7018 welding rod and weld the cutting edge

to the bucket.
8. When welding the floor of the bucket to the top of the
cutting edge:
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A. Start at one end of the bucket and weld toward

the center until one welding rod is used.
B. Start at the center of the bucket and weld in
both directions from center until one welding
rod is used.
C. Start at the other end of the bucket and weld
toward the center until one welding rod is used.
D. Continue to weld the cutting edge to the bucket
using this method until welding is complete.
9. If bucket teeth were removed from the old cutting
edge, install the bucket teeth according to instruc-
tions in this section.
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Bucket - Replace - Replacement of bolt - on cutting edge for

standard bucket

2. Remove all bolt-on cutting edge retaining bolts.
NOTE: If the plow bolt threads or the nut is damaged, it
might be necessary to use an acetylene cutting torch to
remove the plow bolts. do not apply heat to or cut on the
bucket surface. To prevent damage to the bucket surface,
the use of a cutting torch should be restricted to the cutting
edge side only.
3. Thoroughly clean the mounting surface on the bucket
lip with a wire brush to remove any dirt or debris.
4. Install the new cutting edge using new mounting
hardware.
5. Torque the cutting edge mounting bolt nuts to 461 -
569 N·m (340 - 420 lb ft).
RCPH10TLB003GAN 1
1. Cutting edge 2. Plow bolt 3. Nut
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Bucket - Replace - Replacement of bolt - on cutting edge for clam

bucket

2. Remove all cutting edge retaining bolts.
NOTE: If the plow bolt threads or the nut is damaged, it
night be necessary to use an acetylene cutting torch to
remove the plow bolts. do not apply heat to or cut on the
bucket surface. To prevent damage to the bucket surface,
the use of a cutting torch should be restricted to the cutting
edge side only.
3. Thoroughly clean the mounting surface on the bucket
lip with a wire brush to remove any dirt or debris.
4. Install the new cutting edge using new mounting
hardware.
5. Torque the cutting edge mounting bolt nuts to 461 -
569 N·m (340 - 420 lb ft).
RCPH10TLB011BAL 1
1. Clam bucket assembly 3. Plow bolt

2. Cutting edge 4. Nut
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Bucket - Replace - Replacement of tooth shank

NOTE: Bucket teeth are only available on bucket with weld−on cutting edges.
remove the welds that hold the tooth shank in place.
2. Use a grinder to remove any welds or extra material
that will prevent the tooth shank from fitting correctly.
3. See the following illustration for the correct location
of the tooth shank on the cutting edge.
RCPH10TLB052GAL 1
1. 2362 mm (93 in) Short lip and clam bucket - 246 mm (9.685 in).
2. All buckets − 229 mm (9 in).
3. Put tooth shank as close to corner as possible and keep corner of the tooth point even with outer surface of
cutting edge.
4. See the following illustration for weld specifications
and instructions.
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RCPH10TLB049GAL 2
Welding instructions
1. 10 mm (0.394 in) fillet. Weld around each corner 10 mm (0.394 in). Weld two times.
2. 63 mm (2.48 in).
3. 10 mm (0.394 in) fillet. Weld around each corner 10 mm (0.394 in) fillet. Weld both sides and rear of tooth
shank. Weld two times.
4. Long lip bucket 10 mm (0.394 in)Fillet. Weld around each corner 10 mm (0.394 in) fillet. Weld two times.
5. Bent areas of tooth point.
6. Do not weld over edge of blade.
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Bucket - Replace - Replacement of tooth point

1. Heat the part of the tooth point that has been pressed
into the dent on each side of the tooth shank.
2. Bend the tooth point out of the dent on each side of
the tooth shank.
3. Use a pair of pliers to remove the tooth point from the
tooth shank.
4. Install a new tooth point on the tooth shank.
5. Heat the part of the tooth point that will be pressed
into the dent on each side of the tooth shank.
6. Have another person hold the tooth point against the
tooth shank.
7. Use a suitable tool and drive the heated part of the
tooth point into the dent on each side of the tooth
shank.
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Index
Bucket - 300
Bucket - Adjust - Adjustment for return to dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bucket - Adjust - Adjustment of antirollback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Bucket - Exploded view - Adjustment for return to dig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bucket - Exploded view - Antirollback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bucket - Exploded view - Antirollback linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bucket - Exploded view - Bucket cylinder hydraulic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Bucket - Exploded view - Clam cylinder circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bucket - Exploded view - Clam cylinder hydraulic installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bucket - Exploded view - Loader lift bucket control - 580SN-WT only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bucket - Exploded view - Loader lift bucket control - N and SN machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Bucket - General specification - Weld specifications for standard bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bucket - Replace - Replacement of bolt - on cutting edge for clam bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Bucket - Replace - Replacement of bolt - on cutting edge for standard bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Bucket - Replace - Replacement of tooth point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Bucket - Replace - Replacement of tooth shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bucket - Replace - Replacement of weld on cutting edge for standard buckets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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PRINTED IN U.S.A.
47365539 08/07/2012
EN
SERVICE MANUAL
Booms, dippers, and buckets
580N
580SN WT
580SN
590SN
47365539 08/07/2012
84
Contents
Booms, dippers, and buckets - 84
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.100
580N , 580SN WT , 580SN , 590SN
Boom pivoting support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.114

580N , 580SN WT , 580SN , 590SN
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.910
Dipper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.912

580N , 580SN WT , 580SN , 590SN
47365539 08/07/2012
84
Bucket - 100
580N
580SN WT
580SN
590SN
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Contents
Bucket - 100
FUNCTIONAL DATA
Bucket
Drawing - Bucket teeth locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Bucket
Remove Quick Attach Backhoe Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install Quick Attach Backhoe Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Replace - Universal and heavy duty buckets - replacing bottom cutting edge . . . . . . . . . . . . . . . . . . . . . . . 7
Replace - Universal and heavy duty buckets - replacing side cutting edge . . . . . . . . . . . . . . . . . . . . . . . . . 9
Replace - High capacity buckets - bottom cutting edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Replace - High capacity buckets - side cutting edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Replace - Tooth point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Replace - Tooth shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Booms, dippers, and buckets - Bucket
Bucket - Drawing - Bucket teeth locations

Tooth locations for universal and heavy duty buckets
RCPH10TLB144GAL 1
1. Center tooth 5. 304 mm (11.97 in) bucket - 131.1 mm (5.16 in)

2. 12 mm (0.47 in) 406 mm (15.98 in) bucket - 182.2 mm (7.17 in)
3. 457 mm (17.99 in) bucket - 141.18 mm (5.56 in) 457 mm (17.99 in) bucket - 271.36 mm (10.68 in)
610 mm (24.02 in) bucket - 139.5 mm (5.49 in) 610 mm (24.02 in) bucket - 282.5 mm (11.12 in)
762 mm (30 in) bucket - 141.2 mm (5.56 in) 762 mm (30 in) bucket - 286.1 mm (11.26 in)
914 mm (35.98 in) bucket - 156.6 mm (6.17 in) 914 mm (35.98 in) bucket - 434.9 mm (17.12 in)
4. 914 mm (35.98 in) bucket - 297.7 mm (11.72 in) 6. 914 mm (35.98 in) bucket - 573.7 mm (22.59 in)
7. 610 mm (24.02 in) bucket - 425.5 mm (16.75 in)
762 mm (30 in) bucket - 576 mm (22.68 in)
914 mm (35.98 in)bucket - 712.8 mm (28.06 in)
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Tooth locations for high capacity buckets
RCPH10TLB018FAL 2
1. Centerline
2. Center tooth
3. 610 mm (24.02 in) bucket - 98 mm (3.86 in)
762 mm (30 in) bucket - 130.6 mm (5.14 in)
4. Put tooth shank as near corner as possible and keep tooth point 15 mm (0.59 in) outside of cutting edge.
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Bucket - Remove Quick Attach Backhoe Bucket

1. Position backhoe.
RCPH11TLB131AAM 1
2. Position the backhoe bucket.
RCPH11TLB132AAM 2
3. Press both release buttons up to retract pins.
RCPH11TLB133AAM 3
4. Remove backhoe bucket.
RCPH11TLB134AAM 4
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Bucket - Install Quick Attach Backhoe Bucket

1. Move the backhoe into position over the bucket.
RCPH11TLB132AAM 1
2. Press both engage buttons up to pull the pins into

place.
RCPH11TLB133AAM 2
3. Lift the bucket.
RCPH11TLB132AAM 3
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Bucket - Replace - Universal and heavy duty buckets - replacing

bottom cutting edge
1. Remove the bucket teeth. Use carbon arc rod or an
acetylene cutting torch to remove the welds.
NOTICE: When you remove the bottom weld at the rear of the bottom cutting edge, do not cut through the bottom of
the bucket.
remove the welds that hold the bottom cutting edge.
3. Use a grinder to remove any welds or extra metal still
on the bucket so that the new bottom cutting edge will
fit the bucket.
4. Put the new bottom cutting edge in position and make
several tack welds to hold it.
5. See the following illustration for the weld locations
and specifications. Do not make any welds on the
inside of the bucket except the bottom of the bucket
to the bottom cutting edge. Use E7018 welding rod
to weld the bottom cutting edge in position.
RCPH10TLB937ABL 1
1.Universal bucket - 147 mm (5.79 in)
Heavy duty bucket - 151 mm (5.94 in)
2. Universal bucket - 44 mm (1.732 in)
Heavy duty bucket - 47 mm (1.850 in)
3. 10 mm (0.394 in) fillet top and bottom
4. Fill groove between wear plates and bottom cutting edge
5. 6 mm (0.236 in) fillet all around
6. Two pass 6 mm (0.236 in) weld to fill void
6. See the following illustration. Install the corner

bucket teeth and weld the bucket teeth in position.
Use E7018 welding rod.
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RCPH10TLB051GAL 2
1. 14 mm (0.551 in)
2. 20 mm (0.787 in)
3. No weld, top only
4. First weld. 10 mm (0.394 in) flare bevel weld.
Second weld. 10 mm (0.394 in) fillet weld.
5. Bottom all around 8 mm (0.315 in) fillet. weld two times.
6. 8 mm (0.315 in) fillet. weld two times.
7. Weld the remaining bucket teeth to the bottom cutting

edge according to the instructions in this section.
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Bucket - Replace - Universal and heavy duty buckets - replacing

side cutting edge
remove the welds that hold the side cutting edge.
on the bucket so that the new side cutting edge will
fit the bucket.
3. Use E7018 welding rod to weld the side cutting edge
to the bucket with a 6 mm (0.24 in) fillet all around
the side cutting edge.
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Bucket - Replace - High capacity buckets - bottom cutting edge

1. Remove the bucket teeth. Use carbon arc rod or an
acetylene cutting torch to remove the welds.
2. Remove all welds that hold the bottom cutting edge in
position. Use carbon arc rod or an acetylene cutting
torch to remove the welds.
3. Remove the cutting edge from the bucket.
on the bucket so that the new cutting edge will fit the
bucket.
5. Put the new bottom cutting edge in position and use
C-clamps to hold it.
6. See the following illustration for weld locations and
specifications. Use E7018 welding rod to weld the
bottom cutting edge to the bucket.
RCPH10TLB007EAL 1
1. 48 mm (1.89 in)
2. 6 mm (0.24 in) fillet top and bottom
3. Fill groove between wear plates and bottom.
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Bucket - Replace - High capacity buckets - side cutting edge

1. Remove all welds that hold the side cutting edge in
position. Use carbon arc rod or an acetylene cutting
torch to remove the welds.
2. Remove the side cutting edge from the bucket.
on the bucket so that the new side cutting edge will
fit the bucket.
4. Put the side cutting edge in position and use a
C-clamp to hold it.
5. Use E7018 welding rod to weld the side cutting edge
to the bucket. Use a 6 mm (0.24 in) fillet weld all
around the side cutting edge.
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Bucket - Replace - Tooth point

1. Use a hammer and a punch to remove the flex pin
from the tooth point.
2. Install a new tooth point and drive a new flex pin
into the tooth point. Install the flex pin so that the
shoulders are toward the cutting edge.
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Bucket - Replace - Tooth shank

remove the welds that hold the tooth shank.
2. Use a grinder to remove any welds or extra metal that
will prevent the new tooth shank from fitting correctly.
3. If a new cutting edge has been installed, see the
illustrations on the following page for correct location
of the bucket teeth.
4. See the following illustration for weld specifications
for all bucket teeth except the corner bucket teeth
for the universal and the heavy duty buckets. Use
E7018 welding rod to weld the tooth shanks in posi-
tion.
RCPH10TLB006EAL 1
1. 20 mm (0.79 in) no weld
2. No weld
3. 8 mm (0.31 in) fillet both sides. Weld two times.
5. Universal and heavy duty buckets only. See the fol-

lowing illustration for the weld specifications for the
corner bucket teeth. Use E7018 welding rod to weld
the tooth shanks in position.
RCPH10TLB051GAL 2
1. 14 mm (0.55 in)
2. 20 mm (0.79 in)
3. No weld, top only
4. First weld. 10 mm (0.39 in) flare bevel weld.
Second weld. 10 mm (0.39 in) fillet weld.
5. Bottom all around 8 mm (0.31 in) fillet. Weld two times.
6. 8 mm (0.31 in) fillet. Weld two times.
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Index
Bucket - 100
Bucket - Drawing - Bucket teeth locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bucket - Install Quick Attach Backhoe Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Bucket - Remove Quick Attach Backhoe Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Bucket - Replace - High capacity buckets - bottom cutting edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Bucket - Replace - High capacity buckets - side cutting edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Bucket - Replace - Tooth point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Bucket - Replace - Tooth shank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bucket - Replace - Universal and heavy duty buckets - replacing bottom cutting edge . . . . . . . . . . . . . . . . . . . . . . . 7
Bucket - Replace - Universal and heavy duty buckets - replacing side cutting edge . . . . . . . . . . . . . . . . . . . . . . . . . 9
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Boom pivoting support - 114
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Swing tower
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Overview - 580N with mechanical linkage controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Overview - 580SN, 580SN WT, and 590SN with mechanical linkage controls . . . . . . . . . . . . . . . . . . . . . . 10
Overview - All models with pilot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SERVICE
Swing tower
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Booms, dippers, and buckets - Boom pivoting support
Swing tower - Exploded view

The following component list is the same for all machine models with the exception of some of the hardware
dimensions.
(1) Swing tower body
(2) Swing tower lock pin
(3) Upper tower pin with lube fitting
(4) Shim
(5) Snap ring
(6) Boom bumper with hardware
(7) Boom cylinder pin
(8) Shim
(9) Snap ring
(10) Shim
(11) Pin retainer plate with hardware
(12) Boom to Tower Pin
(13) Snap ring
(14) Shim
(15) Swing cylinder pin
(16) Retainer bolt and washer
(17) Snap ring
(18) Shim
(19) Swing tower cylinder
(20) Spacer
(21) Bolt hardware
(22) Swing tower cylinder retaining bracket
(23) Snap ring
(24) Shim(s)
(25) Lower tower pin with lube fitting
(26) Swing tower washer
(27) Shim(s)
(28) Snap ring
(29) Shim(s)
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RCPH10TLB002HAD 1
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Swing tower - Sectional view

The following component list is the same for all machine models with the exception of some of the hardware
dimensions.
(1) Swing tower body
(2) Swing tower lock pin
(3) Upper tower pin with lube fitting
(4) Shim
(5) Snap ring
(6) Boom bumper with hardware
(7) Boom cylinder pin
(8) Shim
(9) Snap ring
(10) Shim
(11) Pin retainer plate with hardware
(12) Boom to Tower Pin
(13) Snap ring
(14) Shim
(15) Swing cylinder pin
(16) Retainer bolt and washer
(17) Snap ring
(18) Shim
(19) Swing tower cylinder (not shown)
(20) Spacer (not shown)
(21) Bolt hardware (not shown)
(22) Swing tower cylinder retaining bracket (not shown)
(23) Snap ring
(24) Shim(s)
(25) Lower tower pin with lube fitting
(26) Swing tower washer
(27) Shim(s)
(28) Snap ring
(29) Shim(s)
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RCPH10TLB006HAD 1
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Swing tower - Overview - 580N with mechanical linkage controls

(1) Backhoe mechanical control valve
(2) Swing cushion valve
(3) Left-hand side swing cylinder
(4) Right-hand side swing cylinder
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RCPH10TLB097GAL 1
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Swing tower - Overview - 580SN, 580SN WT, and 590SN with

mechanical linkage controls
(A) Left-hand side rear view of components
(B) Right-hand side rear view of components
(C) Left-hand side front view of components
(2) Left-hand swing cylinder
(3) Right-hand swing cylinder
(4) Backhoe mechanical control valve
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RCPH10TLB103GAL 1
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Swing tower - Overview - All models with pilot controls

(1) Backhoe pilot control valve
(4) Right-hand swing cylinder
(5) Left-hand swing cylinder
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RCPH10TLB008GAD 1
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Swing tower - Remove

When removing the complete boom assembly as one unit (boom, dipper and tool attachment), provide additional
support to the boom, dipper, and tool attachment.
1. Remove the hose guard.
RCPH10TLB094AAD 1
2. Remove snap ring and washers from rod end pins.
RCPH11TLB036AAL 2
3. Use a suitable driver to remove both swing cylinder

pins.
RCPH10TLB088AAD 3
4. Remove the boom lock pin (3) snap ring (1) and
washer (2).
RCPH10TLB095AAD 4
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5. Remove the boom lock pin (1) and latch arm (2).
RCPH10TLB093AAD 5
6. Attach a suitable lifting device to the swing tower.

NOTE: If required install the boom arm pins on the swing
tower for attachment points.
RCPH10TLB081AAD 6
NOTE: A combination of shims and washers are used to close the spacing between the swing tower and the machine.
The location, orientation and size of the shims and washers are critical to the smooth operation of the swing tower.
Record the location and orientation before removing from the assembly.
7. Remove the snap ring (1) and shims (2) from the
swing tower's lower pin.
RCPH10TLB017AAD 7
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8. Use a suitable driver (1) to remove the lower pin (2).
RCPH10TLB783AAD 8
RCPH10TLB079AAD 9
9. Remove the lubrication fitting (1), snap ring (2) and

shim(s) (3) from the swing tower's upper pin.
RCPH10TLB086AAD 10
10. Drive the upper pin out of the assembly.
RCPH10TLB073AAD 11
Record the location and orientation before removing from the assembly.
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11. Remove the shims and washers from the lower pin
locations on the swing tower.
RCPH10TLB072AAD 12
RCPH10TLB071AAD 13
12. Remove the swing tower from the frame.
RCPH10TLB070AAD 14
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Swing tower - Install

1. On the lower and upper swing tower pins, install a
flat washer(s) and a snap ring to the end without the
lubrication fitting.
2. Move the swing tower into position on the machine.
RCPH10TLB081AAD 1
Place the washers and shims in their original position.
3. On the lower part of the swing tower frame make sure
that the washer with the tab is installed on underside
of the lower top frame plate. The tab must engage
the notch on the swing tower.
RCPH10TLB071AAD 2
4. Position the flat washers and shims in their original

position on the topside of the lower bottom frame
plate.
RCPH10TLB072AAD 3
NOTE: Install pins until the retaining washers rest on the swing tower frame.
5. Install the top swing tower pin with the lubrication
point facing downward.
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6. Install the bottom swing tower pin with the lubrication

fitting upward.
RCPH10TLB017AAD 4
7. Install the remaining snap ring (2) and shim(s) (1) to

the swing tower's upper and lower pins.
RCPH10TLB086AAD 5
8. Install the boom lock pin (1) and boom latch arm (2).
RCPH10TLB093AAD 6
9. Install the snap ring (1) and washer (2) on the boom
lock pin (3).
RCPH10TLB095AAD 7
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10. Move the swing cylinders as necessary to align the

rod eyes with the mounting holes in the swing tower.
11. Install the swing cylinder pins into the rod eyes of the
swing cylinders.
RCPH10TLB054AAD 8
12. From underneath the swing tower, install the washer

(2) and bolt (1).
RCPH10TLB776AAD 9
13. Secure the hose guard (1) in place on the swing

tower with bolts (2).
RCPH10TLB094AAD 10
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Index

Swing tower - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Swing tower - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Swing tower - Overview - 580SN, 580SN WT, and 590SN with mechanical linkage controls . . . . . . . . . . . . . . . . . 10
Swing tower - Overview - All models with pilot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Swing tower - Overview - 580N with mechanical linkage controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Swing tower - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Swing tower - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
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Boom - 910
580N NA
580SN WT NA
580SN NA
590SN NA
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Contents
Boom - 910
FUNCTIONAL DATA
Boom
Exploded view - Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Drawing - Boom latch mechanical linkage machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drawing - Boom latch pilot controlled machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE
Boom
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Booms, dippers, and buckets - Boom
Boom - Exploded view - Boom

Boom components are similar for all models, the difference being in the dimensions of the components.
(1) Pin – Boom arm to dipper arm

(3) Locking bolt
(4) Washer
(5) Spacer
(6) Pin – Cylinder
(7) Shims
(8) Snap ring
(9) Boom guard
(10) Boom bumper pad with hardware
(11) Locking bolt
(12) Pin retainer bracket
(13) Washer
(14) Pin – Boom arm to swing tower
(15) Shims
(16) Washer
(17) Swing tower assembly
(18) Boom lock
(19) Snap ring
(21) Shim
(23) Shim
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RCPH10TLB006HAD 1
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Boom - Drawing - Boom latch mechanical linkage machines

RCPH10TLB084GAL 1
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Boom - Drawing - Boom latch pilot controlled machines

RCPH10TLB045GAL 1
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Boom - Remove
1. Support the boom arm.
RCPH10TLB777AAD 1
2. Identify, tag and disconnect all backhoe hydraulic

hoses.
3. Cap all open ports and hoses.
RCPH10TLB129AAD 2
4. Support the boom cylinder.
RCPH10TLB586AAD 3
5. Remove snap ring and shims from boom cylinder pin.
RCPH10TLB018AAD 4
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6. Remove the boom cylinder pin.
RCPH10TLB584AAD 5
7. Support the boom cylinder on the boom arm.
RCPH10TLB101AAD 6
8. Attach a suitable lifting device to the boom arm as-

sembly.
RCPH10TLB777AAD 7
9. Remove the locking bolt (1) and retainer bracket (2).
RCPH10TLB100AAD 8
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10. Remove the boom arm pin.
RCPH10TLB098AAD 9
11. Remove the boom arm from the machine.
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Boom - Install
1. Attach a suitable lifting device to the boom arm as-
sembly.
2. Align the boom arm assembly with the swing tower.
RCPH10TLB777AAD 1
3. Install the boom arm pin.
RCPH10TLB098AAD 2
4. Secure the boom arm pin with the locking bolt and
retainer bracket. Tighten to a torque of 301 - 407
N·m (222 - 300 lb ft).
RCPH10TLB100AAD 3
5. Align the boom cylinder rod eye with the swing tower
pin opening.
6. Insert the cylinder rod pin.
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7. Secure the pin in place with shims and snap rings.
RCPH10TLB018AAD 4
8. Remove caps and plugs from the hydraulic hoses

and ports.
9. Connect the hydraulic hoses.
RCPH10TLB129AAD 5
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Index
Boom - 910
Boom - Drawing - Boom latch mechanical linkage machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Boom - Drawing - Boom latch pilot controlled machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Boom - Exploded view - Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Boom - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Boom - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Dipper arm - 912
580N
580SN WT
580SN
590SN
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Contents
Dipper arm - 912
FUNCTIONAL DATA
Dipper
Exploded view - Dipper and bucket (580N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N NA
Exploded view - Dipper and bucket (580SN and 580SN-WT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

580SN NA, 580SN WT NA
Exploded view - Dipper and bucket (590SN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

590SN NA
Telescopic dipper
Exploded view - Extendable dipper installation - 580N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
580N NA
Exploded view - Extendable dipper installation - 580SN, 580SN-WT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Exploded view - Extendable dipper installation - 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

590SN NA
SERVICE
Dipper
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Telescopic dipper
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Replace - Extendahoe wear plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

580N NA
Replace - Extendahoe wear plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Booms, dippers, and buckets - Dipper arm
Dipper - Exploded view - Dipper and bucket (580N)

580N NA
RCPH10TLB117GAL 1
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Dipper - Exploded view - Dipper and bucket (580SN and 580SN-WT)

RCPH10TLB118GAL 1
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Dipper - Exploded view - Dipper and bucket (590SN)

590SN NA
RCPH10TLB110GAL 1
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Telescopic dipper - Exploded view - Extendable dipper installation

- 580N
580N NA
RCPH10TLB126GAL 1
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Telescopic dipper - Exploded view - Extendable dipper installation -

580SN, 580SN-WT
RCPH10TLB127GAL 1
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Telescopic dipper - Exploded view - Extendable dipper installation -

590SN
590SN NA
RCPH10TLB119GAL 1
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Dipper - Remove
1. Support backhoe boom for dipper arm removal.
RCPH11TLB074AAL 1
2. Relieve hydraulic pressure by moving all backhoe

control sticks in all directions.
RCPH11TLB077AAL 2
3. Remove the tie securing the protective hose cover.

4. Remove hose clamp.
RCPH11TLB078AAL 3
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5. Identify and disconnect hydraulic hoses.

6. Cap all open tube and hoses.
RCPH11TLB079AAL 4
7. Remove auxiliary hose mounting brackets.
RCPH11TLB059AAL 5
8. Attach a suitable lifting device to the dipper cylinder.
RCPH11TLB060AAL 6
9. Remove snap ring and washers from rod end pin.
RCPH11TLB061AAL 7
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10. Remove cylinder rod end pin.
RCPH11TLB062AAL 8
11. Lower cylinder.
RCPH11TLB063AAL 9
12. Support dipper with appropriate lifting device.
RCPH11TLB064AAL 10
13. Remove bolt securing pin.
RCPH11TLB065AAL 11
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14. Remove dipper pivot pin.
RCPH11TLB066AAL 12
15. Remove dipper arm.
RCPH11TLB067AAL 13
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Dipper - Install
1. Carefully move dipper arm into place.

2. Install dipper pivot pin.
RCPH11TLB066AAL 1
3. Install bolt to secure pin into frame.
RCPH11TLB065AAL 2
RCPH11TLB064AAL 3
5. Move cylinder into position.
RCPH11TLB063AAL 4
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6. Install cylinder rod end pin.
RCPH11TLB062AAL 5
7. Install snap ring and washers on rod end pin.
RCPH11TLB061AAL 6
8. Remove cylinder lifting device.
RCPH11TLB060AAL 7
9. Install auxiliary hose mounting brackets.
RCPH11TLB059AAL 8
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10. Install hose clamp. Install tie to secure protective

hose cover.
RCPH11TLB078AAL 9
11. Verify hydraulic oil level is correct. Fill as needed.
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Telescopic dipper - Remove

1. Remove the bucket or tool that is attached to the

dipper.
2. Support the boom arm for dipper arm removal.
RCPH11TLB074AAL 1
3. Relieve hydraulic pressure by moving all backhoe

control sticks in all directions.
RCPH11TLB077AAL 2
4. Remove the tie securing the protective hose cover.

5. Remove hose clamp.
RCPH11TLB078AAL 3
47365539 08/07/2012
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6. Identify and disconnect hydraulic hoses.

7. Cap all open tube and hoses.
RCPH11TLB079AAL 4
8. Remove auxiliary hose mounting brackets.
RCPH11TLB059AAL 5
9. Attach a suitable lifting device to the dipper cylinder.
RCPH11TLB060AAL 6
10. Remove snap ring and washers from rod end pin.
RCPH11TLB061AAL 7
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11. Remove cylinder rod end pin.
RCPH11TLB062AAL 8
12. Lower cylinder.
RCPH11TLB063AAL 9
13. Support dipper with appropriate lifting device.
RCPH11TLB064AAL 10
14. Remove bolt securing pin.
RCPH11TLB065AAL 11
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15. Remove dipper pivot pin.
RCPH11TLB066AAL 12
16. Remove dipper arm.
RCPH11TLB067AAL 13
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Telescopic dipper - Install

1. Carefully move dipper arm into place.

2. Install dipper pivot pin.
RCPH11TLB066AAL 1
3. Install bolt to secure pin into frame.
RCPH11TLB065AAL 2
RCPH11TLB064AAL 3
5. Move cylinder into position.
RCPH11TLB063AAL 4
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6. Install cylinder rod end pin.
RCPH11TLB062AAL 5
7. Install snap ring and washers on rod end pin.
RCPH11TLB061AAL 6
8. Remove cylinder lifting device.
RCPH11TLB060AAL 7
9. Install auxiliary hose mounting brackets.
RCPH11TLB059AAL 8
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10. Install hose clamp. Install tie to secure protective

hose cover.
RCPH11TLB078AAL 9
11. Verify hydraulic oil level is correct. Fill as needed.
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Telescopic dipper - Replace - Extendahoe wear plates

580N NA
1. Remove the dipper according to the instructions in

this section.
2. Plastic pins are used to hold the wear plates and the
shims in position during assembly. Usually, these
pins wear away during operation. Remove any re-
maining plastic pins. Then remove the wear plates
and the shims.
3. Remove the grease from the sides and the bottom of
the dipper and from the inside of the dipper.
4. Select shims for the side wear plates so that the total
distance from one wear surface to the other is 146 -
147 mm (5.75 - 5.79 in). The wear surface of each
side wear plate must be even with or up to 0.8 mm
(0.031 in) beyond the rails on the dipper.
5. Use new plastic pins to install the side wear plates
and shims.
6. Use new plastic pins to install the top and bottom
wear plates.
7. Apply molydisulfide grease to the rails on the dipper.
8. Install the dipper according to the instructions in this
section.
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Telescopic dipper - Replace - Extendahoe wear plates

1. Remove the dipper according to the instructions in

this section.
2. Remove the bolts, the washers, the wear plates, and
the shims.
3. Remove the grease from the sides and the bottom of
the dipper and from the inside of the dipper.
4. Select shims for the side wear plates so that the to-
tal distance from one wear surface to the other is
146 - 147 mm (5.75 - 5.79 in). The wear surface
of each wear plate must be even with or up to 0.08
mm (0.003 in) beyond the rails on the dipper.
5. Install the shim(s), the side wear plates, the stepped
washers, and the bolts.
NOTE: On 590 Super N machines only, 9.5 mm (0.374 in)
flat washers are used in addition to the stepped washers.
Use a 9.5 mm (0.374 in) flat washer only when there is no
more than one shim installed under that side wear plate.
6. Tighten the bolts to a torque of 70.5 - 77.3 N·m (52 -
57 lb ft).
7. Select shims for the top and bottom wear plates so
that the total distance from one wear surface to the
other is 234 - 235 mm (9.21 - 9.25 in).The wear sur-
face of each wear plate must be even with or up to
0.8 mm (0.031 in) beyond the rails on the dipper.
8. Install the shim(s), the side wear plates, the stepped
washers, and the bolts.
NOTE: On 590 Super N machines only, 9.5 mm (0.374 in)
flat washers are used in addition to the stepped washers.
Use a 9.5 mm (0.374 in) flat washer only when there are
no more than three shims installed under that top or bottom
wear plate.
9. Tighten the cap screws to a torque of 70.5 - 77.3 N·m
(52 - 57 lb ft).
10. Apply molydisulfide grease to the rails on the dipper.
11. Install the dipper according to the instructions in this
section.
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Index
Dipper arm - 912

Dipper - Exploded view - Dipper and bucket (580N) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N NA
Dipper - Exploded view - Dipper and bucket (580SN and 580SN-WT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dipper - Exploded view - Dipper and bucket (590SN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
590SN NA
Dipper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dipper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Telescopic dipper - Exploded view - Extendable dipper installation - 580N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
580N NA
Telescopic dipper - Exploded view - Extendable dipper installation - 580SN, 580SN-WT . . . . . . . . . . . . . . . . . . . . . 7
Telescopic dipper - Exploded view - Extendable dipper installation - 590SN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
590SN NA
Telescopic dipper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Telescopic dipper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Telescopic dipper - Replace - Extendahoe wear plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
580N NA
Telescopic dipper - Replace - Extendahoe wear plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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PRINTED IN U.S.A.
47365539 08/07/2012
EN
SERVICE MANUAL
Platform, cab, bodywork, and decals
580N
580SN WT
580SN
590SN
47365539 08/07/2012
90
Contents
Platform, cab, bodywork, and decals - 90
Machine shields and guards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.105

580N , 580SN WT , 580SN , 590SN
Protections - ROPS and FOPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.114

580N , 580SN WT , 580SN , 590SN
Pneumatically-adjusted operator seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.124

580N , 580SN WT , 580SN , 590SN
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.150
580N , 580SN WT , 580SN , 590SN
Cab interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.151

580N , 580SN WT , 580SN , 590SN
Cab doors and hatches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.154

580N , 580SN WT , 580SN , 590SN
47365539 08/07/2012
90
CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 243 Cab doors and hatches - Install - Rear window - middle 90.154 / 18
47365539 08/07/2012
90
47365539 08/07/2012
90
Machine shields and guards - 105
580N
580SN WT
580SN
590SN
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90.105 / 1
Contents
SERVICE
Engine hood
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
580N T4, 580SN T4, 580SN WT T4, 590SN T4
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Platform, cab, bodywork, and decals - Machine shields and guards
Engine hood - Remove

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1. Remove the bumper bolts (1).

2. Remove the bumpers (3) and front grille screen (2).
RAPH11TLB0049BA 1
3. Raise the hood. Attach safe, lifting equipment to the

hood.
RAPH11TLB0047BA 2
4. Remove the hood strut retaining clips.
RAPH11TLB0046BA 3
5. Disconnect the hood struts from the hood strut posts.
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6. Remove the hood retaining cable bolt (1).

7. Remove the hood bolts (2) and pivot tubes (3).
RAPH11TLB0048BA 4
8. Remove the hood.
RAPH11TLB0047BA 5
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Engine hood - Install

580N T4, 580SN T4, 580SN WT T4, 590SN T4
1. Carefully lower the hood over the cooling package.
RAPH11TLB0047BA 1
2. Install the pivot tubes (3) and hood bolts (2).

3. Install the hood retaining cable and hood retaining
cable bolt (1).
RAPH11TLB0048BA 2
4. Connect the hood struts to the hood strut posts.

5. Attach the hood strut retaining clips.
RAPH11TLB0046BA 3
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90.105 / 5
6. Remove the lifting equipment (1) and lower the hood.
RAPH11TLB0047BA 4
7. Install the front grille screen (2) and bumpers (3).

8. Install the bumper bolts (1).
RAPH11TLB0049BA 5
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Index

Engine hood - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
580N T4, 580SN T4, 580SN WT T4, 590SN T4
Engine hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
580N T4, 580SN T4, 580SN WT T4, 590SN T4
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Protections - ROPS and FOPS - 114
580N
580SN WT
580SN
590SN
47365539 08/07/2012
90.114 / 1
Contents
FUNCTIONAL DATA
Roll Over Protective Structure (ROPS) frame

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Roll Over Protective Structure (ROPS) frame

Remove Rops cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Platform, cab, bodywork, and decals - Protections - ROPS and FOPS
Roll Over Protective Structure (ROPS) frame - Exploded view
RCPH10TLB020FAL 1
1. Nut 6. Mount 11. Mount

2. Washer 7. Bolt 12. Mount
3. Bolt 8. Washer 13. Washer
4. Washer 9. Washer 14. Frame
5. Nut 10. Cab
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Roll Over Protective Structure (ROPS) frame - Remove Rops cab

1. Park the machine on a level surface.
2. Raise the loader and lock the support strut to hold
the loader.
3. Lower the backhoe and stabilizers to the ground.
7. Disconnect the negative ground cable from the bat-
tery, be sure to move the ground cable away from the
battery.
RCPH10TLB030AAL 1
8. Remove the screws from the right hand side and the
left hand side of the front floor mat.
RCPH10TLB318ABL 2
9. Remove the front floor mat from the machine.

10. Pull the cover off of the louver assembly.
RCPH10TLB314ABL 3
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90.114 / 4
11. Push the four tabs inward while pulling louver assem-
bly out.
RCPH10TLB312ABL 4
12. Pull the louver assembly off of the hose. Push the
hose into the cover.
RCPH10TLB313ABL 5
13. Remove the screw from the loader control boot.
RCPH10TLB012ACL 6
14. Remove the boot from the loader control cover. Pull
the boot up turning it inside out. This will allow the
boot to slide through the opening when the cover is
removed.
RCPH10TLB311ABL 7
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15. Remove the three screws from the loader control

cover and remove the cover.
16. Remove the four bolts (1) from the loader control
lever plates. Remove the front plate (2) first then the
back plate (3).
NOTE: Back plate is sealed with silicone sealant.
RCPH10TLB309ABL 8
17. Loosen the screw (1) on the main harness (2) to side
console harness connector and disconnect the con-
nector. Disconnect the main harness to side option
harness connector (3).
RCPH10TLB619AAL 9
18. Remove the bolts securing the loader control rods to

the control lever. Tie the control rods together.
NOTE: Your machine will have either a two spool or three
spool loader control valve.
RCPH10TLB615AAL 10
19. Remove the four screws securing the rubber boot to

the backhoe control tower.
RCPH10TLB316ABL 11
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20. Remove the bolt from the front cover (1) and four
bolts from the rear cover (2) on the backhoe tower.
RCPH10TLB317ABL 12
21. Pull the rubber boot up. This will allow clearance
when removing the covers. Remove the front cover
(1) and the rear cover (2).
RCPH10TLB315ABL 13
22. If equipped remove the rear floor mat. Remove the

bolts on the rear floor plate and remove the plate.
RCPH10TLB621AAL 14
23. Remove the front floor plate.
RCPH10TLB620AAL 15
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24. Remove the bolt (1) from the gear shift lever (2) and
remove the gear shift lever from the transmission
lever (3).
RCPH10TLB617AAL 16
25. Disconnect powershift electrical connectors and

mounting brackets from cab.
NOTE: For powershift machines only.
RCPH10TLB067AAL 17
26. Remove the grill from the machine. Slowly remove

the radiator cap. Install a hose on the drain valve and
drain the radiator into a clean container that holds
approximately 19 l (5 US gal).
RCPH10TLB050AAL 18
27. If equipped with air conditioning see Air condition-

ing - Charging (50.200) for discharging the system.
28. Slowly loosen and disconnect the two brake tubes.
Cap the fittings and plug the brake tube ends.
RCPH10TLB626AAL 19
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29. Put a container under the heater hoses (1) to catch

any remaining coolant when disconnected. Discon-
nect the heater and air conditioning hoses (2). Cap
the fittings and plug the hoses.
RCPH10TLB618AAL 20
30. Remove the cotter pin and clevis pin from the boom
lock lever.
RCPH10TLB045GAL 21
31. Remove the bolt securing the boom lock cable to the
latch.
RCPH10TLB616AAL 22
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32. Disconnect the throttle cable from the fuel injection

pump.
NOTE: 580N only.
RCPH10TLB035AAL 23
33. Remove the throttle cable from the bracket.

NOTE: 580N only.
RCPH10TLB034AAL 24
34. Tag and disconnect the wires for the air filter restric-
tion switch.
RCPH10TLB025AAL 25

nect the air cleaner hose from the turbo. Put a shop
cloth in the turbo opening or the intake opening.
RCPH10TLB024AAL 26
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36. Remove the bolts that fasten the cover to the up-
rights. Use acceptable lifting equipment and remove
the cover and air cleaner as an assembly.
RCPH10TLB023AAL 27
the hole in the curtain. Remove the bolts from the
rubber curtain on the firewall and remove the curtain.
RCPH10TLB240ABL 28
38. Loosen the screw (1) on the main harness to firewall

connector (2). Connector is located on the firewall
under the front console cover.
RCPH10TLB622AAL 29
39. Disconnect the positive (1) and negative (4) wire on

the firewall. Disconnect the main harness to firewall
connector (2). Disconnect the front console options
harness connector (3).
RCPH10TLB625AAL 30
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40. Disconnect the brake tubes from the brake master

cylinder. Cap fittings and plug the brake tube ends.
41. If your machine has a canopy go to Step 42. If the
machine has a cab go to step 44.
NOTE: See illustration in Step 46.
in position. Remove the bolts (1) and washers (2)
that fasten the steering control valve (3) to the steer-
ing column.
43. Go to Step 47.
44. Remove the bolts (4), washers (5), and mounts (6)
that fasten the steering control valve (7) to the cab.
45. Remove the steering control valve (7), mount (8),
and spacer (9) from the cab.
RCPH10TLB167ABL 31
46. Set the control valve out of the way.
RCPH10TLB066GAL 32
1. Bolt 6. Mount
2. Washer 7. Control Valve
3. Control valve 8. Mount
4. Bolt 9. Spacer
5. Washer
47. Remove the nuts (1) and washers (2) from the rear
corners of the cab (10).
NOTE: See illustration Roll Over Protective Structure
(ROPS) frame - Exploded view (90.114) for steps 47 to
50.
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90.114 / 12
48. Remove the bolts (3) and washers (4).

49. Remove the nuts (5) and mounts (6) from the front
corners of the cab (10).
50. Remove the bolts (7) and washers (8) and (9).
51. Use acceptable lifting equipment and lift cab up and
off of machine. When lifting cab up make sure any
cables or hoses still connected to the cab are free
from the machine.
NOTE: Make sure cab is lifted high enough to clear the
backhoe control levers.
RCPH10TLB623AAL 33
1. Lifting points
RCPH10TLB624AAL 34
NOTE: See illustration Roll Over Protective Structure (ROPS) frame - Exploded view (90.114) for the following
step.
52. Remove mounts (11) and (12) and washers (13) from
the frame (14).
Next operation:
Roll Over Protective Structure (ROPS) frame - Install (90.114)
47365539 08/07/2012
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Roll Over Protective Structure (ROPS) frame - Install

Prior operation:
Roll Over Protective Structure (ROPS) frame - Remove (90.114).
NOTE: See illustration Roll Over Protective Structure (ROPS) frame - Exploded view (90.114) for the following
steps.
1. Install washers (13) and mounts (12) and (11) on the
frame (14).
2. Use acceptable lifting equipment and place cab on
the machine. Lower cab slowly and make sure all
wires and hoses are in there proper location.
NOTE: See illustration Roll Over Protective Structure
(ROPS) frame - Exploded view (90.114) for steps 3 to 7.
RCPH10TLB624AAL 1
3. Install the washers (8) and (9) and bolts (7).

4. Install mounts (6) and nuts (5) on the front corners of
the cab (10).
5. Install the washers (4) and bolts (3).
6. Install the washers (2) and nuts (1) on the rear cor-
ners of the cab (10).
7. Tighten the four bolts which secure the cab to the
frame. 298 - 358 N·m (220 - 264 lb ft).
8. If your machine is equipped with a cab go to Step 9.
If it is equipped with a canopy go to Step 12.
NOTE: Refer to illustration Roll Over Protective Struc-
ture (ROPS) frame - Exploded view (90.114) in installa-
tion Step 12.
9. Grease the splines on the steering column and con-
trol valve. Put the spacer (1) and mounts (2) in place.
Have another person hold the steering control valve
(3) in position.
10. Install the mounts (4), washers (5), and bolts (6) that
fasten the steering control valve (3) to the cab.
11. Go to Step 13.
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90.114 / 14
12. Grease the splines on the steering column and con-

trol valve. Have another person hold the steering
control valve (7) in position. Install the washers (8)
and bolts (9) that fasten the steering control valve (7)
to the steering column.
RCPH10TLB066GAL 2
1. Spacer 6. Bolt
2. Mount 7. Control valve
3. Control valve 8. Washer
4. Mount 9. Bolt
5. Washer
13. Remove caps from fittings and plugs from brake

tubes. Connect the brake tubes to the brake master
cylinder.
RCPH10TLB167ABL 3
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14. Connect the positive (1) and negative wire (4) on the
firewall. Connect the main harness to firewall con-
nector (2). Connect the front console options har-
ness connector (3).
RCPH10TLB625AAL 4
15. Tighten the screw (1) on the main harness to firewall

connector (2).
RCPH10TLB622AAL 5
the hole the curtain. Install the curtain and bolts on
the fire wall.
RCPH10TLB240ABL 6
17. Put the cover and air cleaner assembly in position on

the uprights. Install the bolts and flat washers that
fasten the cover to uprights.
RCPH10TLB023AAL 7
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18. Remove the shop cloth from the turbo opening or the
intake opening. Connect the air cleaner hose to the
turbo. Tighten the clamp on the air cleaner hose.
RCPH10TLB024AAL 8
19. Connect the wires to the air restriction switch and

install a new tie strap.
RCPH10TLB025AAL 9
20. Connect the throttle cable to the bracket.

NOTE: 580N only.
RCPH10TLB034AAL 10
21. Connect the throttle cable to the fuel injection pump.

NOTE: 580N only.
RCPH10TLB035AAL 11
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22. Install the bolt securing the boom lock cable to the
latch.
RCPH10TLB616AAL 12
23. Connect the cable to the boom lock lever. Install the
clevis pin and cotter pin.
RCPH10TLB045GAL 13
24. Remove the caps and plugs from the hoses and fit-
tings. Connect the heater (1) and air conditioning (2)
hoses.
RCPH10TLB618AAL 14
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25. Remove the caps and plugs from the fittings and
brake tubes. Connect the two brake line tubes.
RCPH10TLB626AAL 15
26. Connect powershift electrical connectors and mount-

ing brackets to cab.
NOTE: For powershift machines only.
RCPH10TLB067AAL 16
27. Install the gear shift lever (2) on the transmission

lever (3) and tighten the bolt (1).
RCPH10TLB617AAL 17
28. Install the rear floor plate. If equipped install the rear
floor mat.
RCPH10TLB614AAL 18
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1. Rear floor plate mechanical linkage machine

2. Rear floor mat mechanical linkage machine
3. Rear floor plate pilot controlled machine
29. Install the front floor plate.
RCPH10TLB079GAL 19
1. Front floor plate

2. Front floor mat
30. Put the covers (1) (2) on the backhoe control tower
and install the bolts.
RCPH10TLB317ABL 20
31. Install the four screws securing the rubber boot to the
backhoe control tower.
RCPH10TLB316ABL 21
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32. Untie the control rods and install the bolts securing
the loader control rods to the control lever.
NOTE: Your machine will have either a two spool or three
spool loader control valve.
RCPH10TLB615AAL 22
33. Connect the main harness to side console harness

connector (2) and tighten the screw (1). Connect the
main harness to side option harness connector (3).
RCPH10TLB619AAL 23
34. Put a bead of RTV silicone sealant on the mating

surface of the back plate (3) and install the plate.
Install the front plate (2) and tighten the bolts (1).
RCPH10TLB309ABL 24
35. Put the loader control cover in place and push the
vent hose through the hole in the cover. Install the
three bolts on the cover.
36. Put the loader control boot in place and install the
screw.
RCPH10TLB447ABL 25
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37. Push the louver assembly on the hose and push the
assembly onto the cover.
RCPH10TLB313ABL 26
38. Push the cover onto the louver assembly.
RCPH10TLB314ABL 27
39. Put the front floor mat in place. Install the screws on
the right hand side and the left hand side of the front
floor mat.
RCPH10TLB318ABL 28
40. Connect the negative ground cable to the battery.

43. Fill the radiator with the proper amount of coolant.
44. See Brakes - Remove (33.202) for bleeding the
brake system.
45. If equipped with air conditioning see Air condition-
ing - Charging (50.200) for charging the system.
RCPH10TLB030AAL 29
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90.114 / 22
Index

Roll Over Protective Structure (ROPS) frame - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Roll Over Protective Structure (ROPS) frame - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Roll Over Protective Structure (ROPS) frame - Remove Rops cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Pneumatically-adjusted operator seat - 124
580N
580SN WT
580SN
590SN
47365539 08/07/2012
90.124 / 1
Contents
FUNCTIONAL DATA
Pneumatically-adjusted operator seat

Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Seat pneumatic lift system
Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE
Pneumatically-adjusted operator seat

Replace - Pivot safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Disassemble - Pedestal seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Inspect - Pedestal seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Assemble - Pedestal seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disassemble - Mechanical suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Inspect - Mechanical suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Assemble - Mechanical suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Disassemble - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Inspect - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Assemble - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat
Pneumatically-adjusted operator seat - Exploded view
RCIL10TLB002GAF 1
1. Bolt 11. Tether strap 21. Seat cushion

2. Spring 12. Roller bearing 22. Backrest cushion
3. Pin 13. Bushing 23. Armrest
4. Bracket 14. Washer 24. Back tilt knob
5. Retaining ring 15. Upper slide plate assembly 25. Backrest cover
6. Locknut 16. Slide/swivel assembly 26. Lumbar support control
7. Insulator 17. Slide puck 27. Height adjustment switch
8. Lateral isolator shock 18. Adjustable slide puck 28. Slide control lever
9. Roll pin 19. Lateral isolator 29. Swivel lever
10. Lateral isolator control 20. Christmas tree clip
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Seat pneumatic lift system - Exploded view
RCPH10TLB009HAL 1
1. Bolt 12. Fitting 23. Roll pin

2. Washer 13. Air line 24. Isolator control
3. Pedestal 14. Bushing 25. Isolator knob
4. Shaft 15. Wire tie 26. Housing
5. Switch 16. Roller bearing 27. Guide
6. Wire harness 17. Insulator 28. Knob
7. Air spring 18. Bracket 29. Upper housing
8. Lock nut 19. Boot 30. Lower housing
9. Rubber bumper 20. Fore/aft isolator shock 31. Suspension assembly
10. Christmas tree clip 21. Suspension shock 32. Retaining ring
11. Air compressor 22. Spring
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Pneumatically-adjusted operator seat - Replace - Pivot safety switch

1. Remove the guard that protects the switch.
2. Remove the nuts from the seat screws.
3. Remove the switch.
RCPH10TLB776ABL 1
4. Remove the screws and the seat harness wires from

the switch.
RCPH10TLB777ABL 2
5. Discard the switch.

6. Place the seat harness wires onto the new switch.
7. Install and tighten the wire screws.
RCPH10TLB777ABL 3
8. Mount the switch onto the seat screws so that the

arm of the switch is to the rear of the seat.
9. Install and tighten the nuts.
RCPH10TLB776ABL 4
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10. Reinstall the switch guard.
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Pneumatically-adjusted operator seat - Disassemble - Pedestal seat

1. Remove the seat stop.
RCPH10TLB832ABL 1
2. Remove the seat from the slide.
RCPH10TLB833ABL 2
Slide
1. Remove the slide bushings from the left side of the
slide assembly.
RCPH10TLB836ABL 3
2. Remove the adjustable bushings from the right side

of the slide assembly.
RCPH10TLB837ABL 4
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Swivel
1. Remove the cotter pin from the swivel bolt.
RCPH10TLB838ABL 5
2. Remove the nut from the swivel bolt.
RCPH10TLB839ABL 6

4. Remove the top half of the swivel assembly.
RCPH10TLB841ABL 7
5. Remove the bearing separator from the lower half of

the swivel assembly.
6. Remove the bearings.
RCPH10TLB843ABL 8
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Pedestal
1. Place the pedestal in a press. Press down on the
pedestal assembly while holding out on the height
adjustment handle.
RCPH10TLB845ABL 9
2. Loosen and remove the stop bolt.
RCPH10TLB846ABL 10
3. Release the pressure on the press while holding out

on the height adjusting handle.
RCPH10TLB848ABL 11
4. Make sure you see all three of the height adjustment

holes, if not the pedestal is still under spring pres-
sure.
RCPH10TLB849ABL 12
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RCPH10TLB850ABL 13
6. Remove the upper bushing by spreading it at the slot.
RCPH10TLB851ABL 14
7. Remove the lower bushing by spreading it at the slot.
RCPH10TLB852ABL 15
8. Remove the self-locking nut from the height adjust-

ment handle.
RCPH10TLB855ABL 16
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9. Hold onto the height adjustment plunger and remove

the handle bolt.
RCPH10TLB853ABL 17
10. Remove the height adjustment plunger and the

spring.
RCPH10TLB854ABL 18
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Pneumatically-adjusted operator seat - Inspect - Pedestal seat

Prior operation:
Pneumatically-adjusted operator seat - Disassemble - Pedestal seat (90.124)
Slide
1. Check the position locking teeth for damage.
RCPH10TLB835ABL 1
2. Check the slide locking plate, springs, pivots, and

rails for damage.
RCPH10TLB834ABL 2
3. If damage if found, replace the slide and the swivel

as an assembly.
Swivel
1. Inspect the bearing tracks, the bearings, and the
bearing separator plate for wear or damage.
2. Repair or replace as needed.
RCPH10TLB844ABL 3
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Pedestal
1. Inspect the height spring for cracks or damaged coils.
2. Inspect the plunger and plunger spring for wear or
damage.
3. Inspect the bushings for wear or damage.
4. Inspect the height adjustment holes for elongation.
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Pneumatically-adjusted operator seat - Assemble - Pedestal seat

Prior operation:
Pneumatically-adjusted operator seat - Inspect - Pedestal seat (90.124)
Pedestal
1. Place the height adjustment plunger and the spring
into the pedestal shaft.
RCPH10TLB854ABL 1
2. Hold onto the height adjustment plunger and install

the handle bolt.
RCPH10TLB853ABL 2
3. Install the self-locking nut and tighten.

NOTICE: Overtightening the nut can cause binding of the
height adjustment handle.
RCPH10TLB855ABL 3
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4. Install the lower bushing by spreading it at the slot

and sliding it onto the pedestal shaft.
RCPH10TLB852ABL 4
5. Install the upper bushing by spreading it at the slot

and sliding it onto the pedestal shaft.
RCPH10TLB851ABL 5
RCPH10TLB850ABL 6
7. Press the pedestal together while holding out on the

height adjustment handle.
NOTE: Press down until the slot for the stop bolt is visible
through an adjustment hole.
RCPH10TLB848ABL 7
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8. Apply thread locking compound onto the stop bolt.

9. Install and tighten the stop bolt.
10. Remove the seat from the press.
RCPH10TLB847ABL 8
Swivel
1. Place the bearing separator plate onto the lower por-
tion of the swivel.
2. Place the bearings into the separator plate.
RCPH10TLB842ABL 9
3. Install the top half of the swivel assembly over the

separate plate.
4. Place the nut onto the swivel bolt.
5. Hand tighten the swivel nut until there is no play in
the bearing.
6. Tighten the nut two more flats and align it with the
cotter pin hole.
RCPH10TLB841ABL 10
7. Install the cotter pin. Make sure the cotter pin is bent
over enough so it will not interfere with sliding oper-
ations.
RCPH10TLB766ABL 11
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Slide
1. Install the adjustable slide bushings on the right side
of the slide frame.
2. Lubricate the nonadjustable slide bushings with
molydisulfide grease.
3. Install the nonadjustable slide bushings on the left
side of the slide frame.
RCPH10TLB837ABL 12
4. Align the adjuster holes with the adjustable bushings.
RCPH10TLB775ABL 13
5. Adjust the bushings for the side to side motion of the

seat.
NOTE: Slides adjusted too tightly can cause difficulty ad-
justing the seat fore and aft.
RCPH10TLB829ABL 14
Seat
1. Install the seat.
2. Install and tighten the seat stop.
RCPH10TLB832ABL 15
Next operation:
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Seat restraints - Install (90.151)
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Pneumatically-adjusted operator seat - Disassemble - Mechanical

suspension seat
Cushions
1. Push up on the bottom seat cushion and remove.
RCPH10TLB755ABL 1
2. Remove the retaining screws for the back cushion.
RCPH10TLB756ABL 2
3. Pull forward and lift the back cushion off of the mount-
ing tabs to remove.
RCPH10TLB757ABL 3
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Lumber adjustment
1. Drive the roll pin out of the lumbar adjustment knob.
RCPH10TLB759ABL 4
2. Remove the mounting screws and the lumber adjust-

ment knob.
RCPH10TLB758ABL 5
3. Drill out the rivets and remove the lumbar assembly.
RCPH10TLB761ABL 6
Recliner
1. Remove the mounting screws and the stop plate from
the rear of the seat bottom.
RCPH10TLB762ABL 7
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2. Remove the four nuts and the four washers from the
seat bottom.
3. Remove the seat bottom and the seat back from the
slide/swivel assembly.
RCPH10TLB778ABL 8
4. Pivot the back rest forward and remove the four nuts
and the two bolts that mount the seat bottom to the
seat back.
RCPH10TLB817ABL 9
5. Remove the seat bottom.

6. Remove the spring retaining nut.
RCPH10TLB816ABL 10
RCPH10TLB815ABL 11
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8. Remove the spring from the pivot pin.
RCPH10TLB814ABL 12
9. Remove the arm rest from the seat back.
RCPH10TLB813ABL 13
10. Remove the spring for the recliner handle from the
arm rest bracket.
RCPH10TLB801ABL 14
11. Remove the handle return spring from the recliner.
RCPH10TLB810ABL 15
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12. Remove the nut from the recliner.
RCPH10TLB809ABL 16
13. Remove the washer from the recliner.
RCPH10TLB808ABL 17
14. Remove the bushing from the recliner, remove the

arm rest from the seat back.
RCPH10TLB807ABL 18
15. Remove the handle from the seat back.
RCPH10TLB802ABL 19
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16. Remove the two bolts from the recliner bracket, re-
move the bracket.
RCPH10TLB803ABL 20
17. Remove the retainer and recliner gear.
RCPH10TLB804ABL 21
Slide
1. Remove the slide bushings from the left side of the
slide assembly.
RCPH10TLB763ABL 22
2. Remove the adjustable slide bushings from the right

side of the slide assembly.
RCPH10TLB764ABL 23
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Swivel
1. Remove the cotter pin from the swivel bolt.
RCPH10TLB766ABL 24
2. Place a suitable wedge under the bottom of the

swivel bolt to hold it into the swivel assembly.
RCPH10TLB767ABL 25
RCPH10TLB768ABL 26
4. Remove the bushing from the swivel bolt.

5. Remove the top half of the swivel assembly.
RCPH10TLB769ABL 27
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6. Remove the bearing separator from the lower half of

the swivel assembly.
RCPH10TLB770ABL 28
7. Remove the bearings.
RCPH10TLB771ABL 29
Suspension
1. If you have not already done so, obtain access to the
suspension system.
A. Remove the upper tether mounting bolts and
nuts.
RCPH10TLB782ABL 30
B. Remove the front slide/swivel mounting bolts.
RCPH10TLB783ABL 31
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C. Remove the slide/swivel assembly.

NOTE: The slide/swivel assembly does not have to be dis-
assembled.
RCPH10TLB784ABL 32
2. Remove the lower mounting bolts and the tether

straps, keep all of the components together for the
tether straps.
RCPH10TLB787ABL 33
3. Remove the front mounting nuts and washers.

4. Remove the suspension assembly from the seat
mount.
RCPH10TLB785ABL 34
5. Remove the roll pin from the height/weight adjuster

knob and remove the knob.
NOTE: Remove the knob to prevent damage while remov-
ing the boot for the suspension assembly.
RCPH10TLB781ABL 35
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6. Remove the boot from the suspension assembly.
RCPH10TLB786ABL 36
7. • If reusing the boot, pry out the retaining pins.

Place the cutting edge of the side cutters close
to the pressed in button shaft.
• If replacing the boot, cut the retaining pins with
the side cutter and remove the pins.
RCPH10TLB828ABL 37
8. Place the suspension assembly in a press.

9. Push down on the suspension.
RCPH10TLB788ABL 38
10. Remove the nut on the shock.

11. Remove the bolt from the shock.
RCPH10TLB789ABL 39
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12. Slowly release the pressure on the suspension as-

sembly.
RCPH10TLB790ABL 40
13. Remove the nut from the upper and lower pivots.
RCPH10TLB791ABL 41
14. Pull the pivot bolt back just far enough to remove the
shock from the suspension assembly.
RCPH10TLB793ABL 42
15. Remove the upper pivot bolt.

16. Remove the upper plate from the suspension assem-
bly.
RCPH10TLB792ABL 43
17. Disassemble the height/weight adjustment assembly

as needed.
1. Remove the top half of the upper plate.
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B. Remove the gear for the height/weight knob.

NOTE: You do not have remove the knob from the gear.
RCPH10TLB797ABL 44
C. Remove the adjustment gear.
RCPH10TLB797ABL 45
D. Remove the bushing for the adjustment gear.
RCPH10TLB798ABL 46
18. Remove the lower pivot bolt for the lower plate of the
suspension assembly.
RCPH10TLB794ABL 47
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19. Remove the scissor assembly.
RCPH10TLB795ABL 48
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Pneumatically-adjusted operator seat - Inspect - Mechanical

suspension seat
Prior operation:
Pneumatically-adjusted operator seat - Disassemble - Mechanical suspension seat (90.124)
Slide
1. Check the position locking teeth for damage.
RCPH10TLB765ABL 1
2. Check the slide locking plate, springs, pivots, and

rails for damage.
RCPH10TLB831ABL 2
3. If damage if found, replace the slide and the swivel

as an assembly.
Swivel
1. Inspect the bearing tracks, the bearings, and the
bearing separator plate for wear or damage.
RCPH10TLB772ABL 3
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Suspension
1. Inspect the slider blocks and the bushings for wear
and damage.
RCPH10TLB796ABL 4
2. Inspect the threads and the teeth of the height/weight

adjustment gear and the knob gear.
RCPH10TLB797ABL 5
3. Inspect the bushing on the bottom of the gear.
RCPH10TLB798ABL 6
4. Inspect the rubber stops.
RCPH10TLB799ABL 7
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5. Inspect the shock for leaks.

6. Inspect the bushings for wear.
RCPH10TLB007ACL 8
7. Inspect the spring for damage.

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Pneumatically-adjusted operator seat - Assemble - Mechanical

suspension seat
Prior operation:
Pneumatically-adjusted operator seat - Inspect - Mechanical suspension seat (90.124)
Suspension
1. Install the slider blocks on the lower plate as shown.
NOTE: Do not lubricate the slider blocks.
RCPH10TLB818ABL 1
2. Install the scissor assembly.
RCPH10TLB795ABL 2
3. Lubricate the pivot bushing with molydisulfide

grease.
4. Install the pivot bolt and the nut in the slotted hole on
the lower plate of the suspension assembly.
NOTE: The 'L' portion of the pivot bolt goes to the inside of
the suspension assembly.
5. Tighten the nut.
RCPH10TLB819ABL 3
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6. Install the height/weight adjustment assembly as

needed.
A. Lubricate the bushing for the bottom of the gear
with molydisulfide grease.
B. Place the bushing on the lower half of the upper
plate for the suspension system.
RCPH10TLB821ABL 4
C. Lubricate the gear threads with molydisulfide

grease.
D. Install the gear so it aligns with the bushing.
RCPH10TLB822ABL 5
E. Install the gear for the height/weight adjustment

knob.
RCPH10TLB797ABL 6
F. Install the top half of the upper plate.

7. Install the upper plate assembly.
8. Install the upper pivot bolt in the slotted hole.
RCPH10TLB792ABL 7
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9. Start the pivot bolt into the scissor assembly.

NOTE: The “L” portion of the pivot bolt goes to the inside
of the suspension assembly.
RCPH10TLB824ABL 8
10. Install the shock.
RCPH10TLB825ABL 9
11. Insert the pivot bolt completely and install and tighten
the nut.
12. Place the suspension assembly into a press.
13. Compress the spring to mount the shock.
14. Install the bolt and nut for the shock.
RCPH10TLB788ABL 10
15. Slowly release the pressure on the suspension as-

sembly.
16. Check for proper operation of the weight/height ad-
justment.
NOTE: Turn the handle to the '+' to raise the plate and apply
more pressure the spring, turn the handle to the '-' will to
lower the plate and decrease the pressure on the spring.
RCPH10TLB826ABL 11
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17. Install the boot. Use a non-marring hammer to tap in

the retaining pins.
RCPH10TLB827ABL 12
18. Place the suspension assembly onto the stand,

19. Install and tighten the front mounting nuts and wash-
ers.
RCPH10TLB785ABL 13
20. Install the tether straps on the rear of the stand.
RCPH10TLB787ABL 14
Swivel
1. Place the bearing separator plate onto the lower por-
tion of the swivel.
RCPH10TLB773ABL 15
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2. Place the bearings into the separator plate.
RCPH10TLB774ABL 16
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3. Install the top half of the swivel assembly over the

separate plate.
4. Place the nut onto the swivel bolt.
5. Hand tighten the swivel nut until there is no play in
the bearing.
6. Tighten the nut two more flats and align it with the
cotter pin hole.
RCPH10TLB769ABL 17
7. Install the cotter pin. Make sure the cotter pin is bent
over enough so it will not interfere with sliding oper-
ations.
RCPH10TLB766ABL 18
Slide
1. Install the adjustable slide bushings on the right side
of the slide frame.
RCPH10TLB764ABL 19
2. Lubricate the bushings with molydisulfide grease.

3. Install the nonadjustable slide bushings on the left
side of the slide frame.
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4. Align the adjuster holes with the adjustable bushings.
RCPH10TLB775ABL 20
5. Adjust the bushings for the side to side motion of the

seat.
NOTE: Slides adjusted too tightly can cause difficulty ad-
justing the seat fore and aft.
RCPH10TLB829ABL 21
6. Install the slide/swivel assembly onto the suspen-

sion.
RCPH10TLB784ABL 22
A. Install and tighten the upper tether mounting

bolts and nuts.
RCPH10TLB782ABL 23
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B. Install and tighten the front slide/swivel mount-

ing bolts.
RCPH10TLB783ABL 24
Seat
1. Install the seat.
2. Install the seat stop.
RCPH10TLB762ABL 25
3. If removed, place the height/weight adjuster knob

onto the shaft and install a new roll pin.
RCPH10TLB780ABL 26
Recliner
1. Place the gear onto the pivot.
2. Drive a new retainer onto the pivot.
NOTE: The gear must pivot freely.
RCPH10TLB805ABL 27
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3. Install the brackets,

4. Install and tighten the two bolts.
RCPH10TLB803ABL 28
5. Place the handle into the seat back.
RCPH10TLB802ABL 29
6. Place the seat back onto the arm rest pivot.

NOTE: Align the handle pin into the recliner gear.
RCPH10TLB806ABL 30
7. Install the bushing onto the recliner.
RCPH10TLB807ABL 31
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8. Install the washer onto the recliner.
RCPH10TLB808ABL 32
9. Install and tighten the nut onto the recliner.
RCPH10TLB809ABL 33
10. Place the handle return spring into the recliner.
RCPH10TLB810ABL 34
11. Install the handle return spring into the mounting hole
in the arm rest.
RCPH10TLB811ABL 35
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12. Make sure the handle return spring is completely

seated into the mounting hole.
RCPH10TLB812ABL 36
13. Install the arm rest into the seat back.
RCPH10TLB813ABL 37
14. Place the spring onto the pivot pin and hook the
spring onto the seat back.
RCPH10TLB814ABL 38
RCPH10TLB815ABL 39
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16. Install and tighten the self-locking nut.
RCPH10TLB816ABL 40
17. Attach the seat bottom to the seat back.

A. Place the seat bottom into the arm rests.
B. Install and tighten the bolts and nuts.
RCPH10TLB817ABL 41
18. Place the spacers onto the slide/swivel assembly.
RCPH10TLB779ABL 42
19. Place the seat frame onto the slide/swivel assembly.

20. Tighten the four mounting bolts.
RCPH10TLB778ABL 43
21. Check the recliner for proper operation.
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Lumbar
1. Place the lumbar assembly into position on the seat
back and install new rivets.
RCPH10TLB761ABL 44
2. Put the knob and shaft bushing onto the shaft.

3. Mount the bushing to the seat back.
RCPH10TLB758ABL 45
4. Install a new roll pin into the knob.
RCPH10TLB760ABL 46
Cushion
1. Install the back seat cushion by aligning the retaining
tabs with the slots.
RCPH10TLB830ABL 47
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2. Install and tighten the seat back retaining screws.
RCPH10TLB756ABL 48
3. Align the retaining tabs with the slots and push the
seat bottom into position.
RCPH10TLB755ABL 49
Next operation:
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Pneumatically-adjusted operator seat - Disassemble - Air

suspension seat
1. Loosen and remove the four bolts from the seat as-
sembly.
2. Remove the seat assembly from the base.
RCPH10TLB858ABL 1
3. Place the seat assembly on the workbench.

4. Cut and remove the plastic clips from the backrest
cover.
5. Remove the backrest cover.
RCPH10TLB922ABL 2
6. Push in on the plastic retainer and remove the lumbar

support adjustment knob.
RCPH10TLB924ABL 3
7. Remove the mounting screw from the housing for the

lumber support adjustment knob.
RCPH10TLB923ABL 4
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8. Disconnect the cable from the lumbar support.

9. Remove the cable and housing assembly.
RCPH10TLB923ABL 5
10. Remove the armrests.

A. Tilt the armrest up until it is against the upper
stop.
B. Push in on the armrest as shown.
C. Rotate the armrest counter-clockwise past the
upper stop.
RCPH10TLB857ABL 6
D. Remove the armrest from the seat.
RCPH10TLB856ABL 7
11. Loosen and remove the two Allen head bolts from
the seat stop.
12. Remove the seat stop from the upper slide plate.
RCPH10TLB859ABL 8
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13. Loosen the two Allen head bolts in the two slide
pucks on the right side of the upper slide plate.
NOTE: Slide the upper plate fore or aft until the set screws
are visible through the holes in the side rail.
RCPH10TLB861ABL 9
14. Lift the handle to release the lock on the upper slide
plate.
RCPH10TLB863ABL 10
15. Move the upper slide plate forward and remove from
the slide/swivel assembly.
RCPH10TLB864ABL 11
16. Use acceptable tools and remove the roll pin and
retaining ring from the slide control lever (1).
17. Remove the return spring and the slide control lever
from the upper slide plate assembly.
18. Repeat this procedure and remove the swivel control
lever (2) from the upper slide plate assembly.
RCPH10TLB916ABL 12
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19. Use acceptable tools and remove the roll pin and
retaining ring from the slide latch.
20. Remove the return spring and the slide latch from the
upper slide plate assembly.
RCPH10TLB917ABL 13
21. Use a soft hammer and remove the slide pucks from
the slide/swivel assembly.
RCPH10TLB865ABL 14
22. Loosen and remove the two 5/16 inch bolts from the
front side of the slide/swivel assembly.
RCPH10TLB867ABL 15
23. Loosen and remove the two 3/8 inch bolts and the
two tether straps from the rear of the slide/swivel as-
sembly.
RCPH10TLB868ABL 16
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24. Remove the slide/swivel assembly from the lateral

isolator plate.
RCPH10TLB869ABL 17
25. Loosen and remove the two bolts from the swivel
contact switch assembly.
26. Remove the switch from the lateral isolator plate.
RCPH10TLB870ABL 18
27. Remove the two screws from the swivel contact

switch.
28. Disconnect the wiring harness from the swivel con-
tact switch.
RCPH10TLB872ABL 19
29. Disconnect the wiring harness from the height adjust-

ment switch.
RCPH10TLB871ABL 20
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30. Remove the two bolts from the mounting bracket for
the height adjustment switch.
31. Remove the height adjustment switch assembly.
RCPH10TLB873ABL 21
32. From the rear of the height adjustment switch, press

in on the top and bottom tabs and push the switch for-
ward until the tabs are free of the mounting bracket.
33. Remove the height adjustment switch from the
mounting bracket.
RCPH10TLB874ABL 22
34. Loosen and remove the four bolts from the lateral
isolator plate.
RCPH10TLB875ABL 23
35. Remove the isolator plate from the upper housing.
RCPH10TLB876ABL 24
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36. Turn the isolator plate over and place on the work-
bench.
37. Use acceptable tools and remove the two isolator
springs from the isolator plate.
RCPH10TLB909ABL 25
38. Use acceptable tools and remove the nut from the
isolator shock.
RCPH10TLB910ABL 26
39. Remove the top washer and rubber insulator from the
shock.
RCPH10TLB911ABL 27
40. Use acceptable tools and remove the retaining ring

from the lateral isolator shock.
RCPH10TLB912ABL 28
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41. Remove the pin from the isolator shock.
RCPH10TLB913ABL 29
42. Remove the shock from the isolator plate.
RCPH10TLB914ABL 30
43. Use acceptable tools and remove the two roll pins
from the lateral isolator control.
RCPH10TLB909ABL 31
44. Use acceptable tools and remove the bolts (1) from
the isolator control mounting bracket.
45. Remove the lateral isolator control (2) from the iso-
lator plate.
RCPH10TLB909ABL 32
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46. Slide bottom of the isolator plate to the left until the
isolator roller bearings are exposed.
47. Remove the rollers bearings from the shaft.
48. Slide the bottom of the isolator plate to the right until
the isolator roller bearings are exposed
49. Remove the roller bearings from the shaft.
NOTE: Illustration is for reference only.
RCPH10TLB909ABL 33
50. Remove the plastic pins from the boot assembly and
fold the boot down to the base plate. Note the loca-
tion of the tether straps behind the boot.
RCPH10TLB877ABL 34
51. Loosen and remove the two bolts from the fore/aft
isolator shock mounting bracket.
52. Remove the bracket from the upper housing plate.
53. Allow the other end of the isolator shock to hang from
the suspension arm.
RCPH10TLB878ABL 35
54. Loosen and remove the two bolts from the fore/aft
isolator control. Retain the bolts for reassembly.
RCPH10TLB879ABL 36
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55. Slide the upper housing to the rear and lift the hous-
ing free of the roller bearings on the rear suspension
arms.
RCPH10TLB880ABL 37
56. Slide the upper housing forward and lift the housing
free of the roller bearings on the front suspension
arms. Note the location of the rubber bumpers on
the upper housing for reassembly.
RCPH10TLB881ABL 38
57. Remove the two wide roller bearings from the front
suspension arms.
RCPH10TLB882ABL 39
58. Remove the two narrow roller bearings from the rear
suspension arms.
RCPH10TLB883ABL 40
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59. Remove the bushing and the isolator control from the
suspension arm.
RCPH10TLB884ABL 41
60. Use acceptable tools and remove the roll pins from
each end of the isolator control.
61. Remove the two plastic bushings, the two springs,
and the latch assembly from the isolator control.
RCPH10TLB907ABL 42
62. Use acceptable tools and remove the roll pin from
the control housing.
63. Remove the isolator control knob from the housing.
RCPH10TLB907ABL 43
64. Remove the two bushings and the isolator shock

from the suspension arm.
RCPH10TLB885ABL 44
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65. Place an acceptable block between the suspension

assembly and the front of the lower housing assem-
bly.
RCPH10TLB886ABL 45
66. Note the location of the three wire ties on the lower
housing assembly.
RCPH10TLB918ABL 46
67. Cut and remove the three wire ties from the wiring
harness.
RCPH10TLB892ABL 47
68. Note the location of the two wire ties on the suspen-
sion assembly.
RCPH10TLB918ABL 48
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69. Cut and remove the wire ties.
RCPH10TLB887ABL 49
70. Disconnect the wiring harness from the air compres-

sor assembly.
RCPH10TLB888ABL 50
71. Loosen the air line fitting and allow the air to escape
from the air spring assembly.
72. Remove the air line from the air spring.
RCPH10TLB889ABL 51
73. Loosen and remove the two bolts from the air com-
pressor mounting bracket.
RCPH10TLB890ABL 52
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74. Remove the air compressor assembly.
RCPH10TLB891ABL 53
75. Loosen and remove the four bolts from the pedestal
mounting plate.
76. Remove the pedestal from the lower housing assem-
bly.
RCPH10TLB894ABL 54
77. Loosen and remove the lower screw from the air
spring.
RCPH10TLB895ABL 55
78. Loosen and remove the bolt from the top of the air
spring.
RCPH10TLB893ABL 56
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79. Remove the air spring assembly.
RCPH10TLB896ABL 57
80. Cut and remove the plastic pins from the rubber boot.
RCPH10TLB897ABL 58
81. Remove the rubber boot from the lower housing as-
sembly.
RCPH10TLB898ABL 59
82. Loosen and remove the nut from the shaft.
RCPH10TLB906ABL 60
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83. Use acceptable tools and remove the shaft from the
lower housing assembly.
RCPH10TLB905ABL 61
84. Tilt the suspension assembly forward.

85. Turn the suspension assembly counter-clockwise
and remove from the lower housing.
RCPH10TLB903ABL 62
86. Remove the two roller bearings (1) from the shaft.
87. Use acceptable tools and remove the two plastic
bushings (2) from the tube.
RCPH10TLB899ABL 63
88. Remove the retaining clip from the isolator shock.
RCPH10TLB900ABL 64
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89. Remove the isolator shock and two plastic bushings

from the suspension assembly.
RCPH10TLB901ABL 65
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Pneumatically-adjusted operator seat - Inspect - Air suspension

seat
Prior operation:
Pneumatically-adjusted operator seat - Disassemble - Air suspension seat (90.124)
1. Inspect the seat cushion, backrest cushion, arm rests

and lumbar support control for wear and damage.
2. Inspect the upper slide plate assembly, swivel con-
trol, slide control, and slide latch for wear and dam-
age.
3. Inspect the slide/swivel assembly and slide pucks for
wear and damage.
4. Inspect the swivel switch, height adjustment switch,
and wire harness for damage.
5. Inspect the lateral isolator plate, isolator shock, bush-
ings, springs, roller bearings, and control for wear
and damage.
6. Inspect the boot assembly for damage.
7. Inspect the upper housing and rubber bumpers for
wear and damage. Use new parts as required.
8. Inspect the suspension assembly and roller bearings
9. Inspect the fore/aft isolator shock and bushings for
wear and damage.
10. Inspect the fore/aft isolator control and bushing for
wear and damage.
11. Inspect the suspension isolator shock and bushings
12. Inspect the air compressor, air line, and wiring har-
ness for wear and damage.
13. Inspect the air spring for wear and damage.
14. Insect the lower housing, bearing shaft, and rubber
bumper for wear and damage.
15. Inspect the pedestal for damage.
16. Repair or replace worn or damaged parts as needed.
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Pneumatically-adjusted operator seat - Assemble - Air suspension

seat
Prior operation:
Pneumatically-adjusted operator seat - Inspect - Air suspension seat (90.124)
1. Install the isolator shock and the two plastic bushings

onto the suspension assembly.
RCPH10TLB901ABL 1
2. Use acceptable tools and install the retaining clip

onto isolator shock.
RCPH10TLB902ABL 2
3. Lubricate the two roller bearings (1) with molydisul-

fide grease and install onto the shaft.
RCPH10TLB899ABL 3
4. Install the two plastic bushings (2) into the tube.
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5. Install the suspension assembly roller bearings into

the lower housing at a slight angle, as shown.
RCPH10TLB903ABL 4
6. Turn the suspension assembly clockwise and align

the rear tube into the lower housing assembly.
7. Install the shaft into the lower housing assembly.
RCPH10TLB904ABL 5
8. Install and tighten the nut on the shaft.
RCPH10TLB906ABL 6
9. Install the rubber boot over the suspension assembly

and onto the lower housing assembly.
RCPH10TLB898ABL 7
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10. Install the plastic pins into the lower mounting holes
of the rubber boot.
RCPH10TLB919ABL 8
11. Install the air spring assembly into the suspension

assembly.
RCPH10TLB896ABL 9
12. Install and tighten the bolt into the top of the air
spring.
RCPH10TLB893ABL 10
13. Install and tighten the screw into the bottom of the air
spring.
RCPH10TLB895ABL 11
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14. Install the pedestal onto the lower housing.

15. Install the tether straps between the rubber boot and
lower housing.
16. Install and tighten the four bolts for the pedestal
mounting plate.
17. Drive the pins into the mounting holes in the lower
housing assembly.
RCPH10TLB894ABL 12
18. Install the air compressor into the suspension as-

sembly.
RCPH10TLB891ABL 13
19. Install and tighten the two air compressor mounting

bolts.
RCPH10TLB890ABL 14
20. Install the air line into the fitting on the air spring.
21. Tighten the fitting nut.
RCPH10TLB889ABL 15
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22. Connect the air compressor wiring harness.
RCPH10TLB888ABL 16
23. Install three wire ties for the wiring harness on the
lower housing assembly.
RCPH10TLB918ABL 17
24. Install two wire ties on the suspension assembly.
RCPH10TLB918ABL 18
25. Install the two plastic bushings and the isolator shock
onto the suspension assembly. Make sure that the
white plastic bushing is on the outside.
RCPH10TLB885ABL 19
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26. Assemble the parts of the isolator control.
RCPH10TLB907ABL 20
27. Install the isolator control and plastic bushing onto

the suspension assembly.
RCPH10TLB884ABL 21
28. Lubricate the two narrow roller bearings with moly-

disulfide grease.
29. Install the narrow roller bearings onto the rear shafts
RCPH10TLB883ABL 22
30. Lubricate the two wide roller bearings with molydisul-

fide grease.
31. Install the wide roller bearings onto the front shafts
RCPH10TLB882ABL 23
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32. Install the upper housing slide rail onto the wide roller
bearings on the suspension assembly. Make sure
the rubber bumpers are facing to the rear of the sus-
pension assembly.
RCPH10TLB881ABL 24
33. Slide the upper housing to the rear until the narrow
roller bearings engage the slide rails of the upper
housing.
RCPH10TLB880ABL 25
34. Install and tighten the two bolts in the fore/aft isolator
control.
NOTE: Ensue you use the same bolts that you removed
during disassembly.
RCPH10TLB879ABL 26
35. Install the bracket on the upper housing plate.

36. Position the isolator shock in the upper housing plate.
37. Install and tighten the two bolts in the fore/aft isolator
mounting bracket.
RCPH10TLB878ABL 27
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38. Slide the rubber boot into position on the upper hous-
ing.
39. Install the plastic pins into the mounting holes in the
rubber boot.
40. Drive the pins into the mounting holes in the upper
housing.
RCPH10TLB920ABL 28
41. Slide the bottom of the isolator plate to the left until
the holes for the roller bearings are visible.
42. Lubricate the two roller bearings with molydisulfide
grease.
43. Install the roller bearings onto the shafts of the isola-
tor plate.
44. Slide the bottom of the isolator plate to the right until
the holes for the roller bearings are visible.
45. Lubricate the two roller bearings with molydisulfide
grease.
46. Install the roller bearings onto the shafts of the isola- RCPH10TLB909ABL 29
tor plate.
NOTE: Illustration is for reference only.
47. Install the lateral isolator control (2) onto the isolator
plate.
48. Install and tighten the bolts (1) in the mounting
bracket.
RCPH10TLB909ABL 30
49. Use acceptable tools and install the two roll pins in
the isolator control.
RCPH10TLB909ABL 31
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50. Install the isolator shock and two plastic bushings

into the mounting brackets on the isolator plate.
RCPH10TLB914ABL 32
51. Install the pin into the isolator shock.
RCPH10TLB913ABL 33
52. Install the retaining clip onto the pin.
RCPH10TLB912ABL 34
53. Install the rubber insulator and top washer onto the
shock.
RCPH10TLB911ABL 35
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54. Install and tighten the lock nut on the shock.
RCPH10TLB910ABL 36
55. Install the two isolator springs on the isolator plate.
RCPH10TLB909ABL 37
56. Turn the isolator plate over and install onto the upper
housing.
RCPH10TLB876ABL 38
57. Install and tighten the four bolts that mount the lateral
isolator plate to the upper housing.
RCPH10TLB875ABL 39
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58. Install the height adjustment switch into the mounting

bracket.
RCPH10TLB874ABL 40
59. Install the height adjustment switch assembly.

60. Install and tighten the bolts in the mounting bracket
for the height adjustment switch.
RCPH10TLB873ABL 41
61. Connect the wiring harness to the height adjustment

switch.
RCPH10TLB871ABL 42
62. Connect the wiring harness to the swivel switch.

63. Tighten the screws to secure the harness on the
swivel switch.
RCPH10TLB872ABL 43
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64. Install the swivel contact switch assembly on the lat-

eral isolator plate.
65. Install and tighten the two bolts.
RCPH10TLB870ABL 44
66. Install the slide/swivel assembly on the lateral isola-

tor plate.
RCPH10TLB869ABL 45
67. Install the two 3/8 inch bolts through the tether strap
mounting holes.
68. Install and tighten the bolts into the swivel plate
mounting holes.
69. Install and tighten the bolts into the swivel plate
mounting holes.
RCPH10TLB868ABL 46
70. Install and tighten the two 5/16 inch bolts into the
swivel plate mounting holes.
RCPH10TLB867ABL 47
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71. Place the adjustable slide pucks on the slide/swivel

assembly, as shown.
72. Use a soft hammer to install the side pucks.
RCPH10TLB866ABL 48
73. Use acceptable tools and install the return spring and
slide latch on the upper plate assembly.
74. Use acceptable tools and install the roll pin and the
retaining clip on the slide latch.
RCPH10TLB917ABL 49
75. Place the slide control lever (1) and the swivel lever
(2) on the upper slide plate assembly.
76. Use acceptable tools and install the spring, roll pin
and the retaining ring to secure the levers on the
upper slide plate.
RCPH10TLB916ABL 50
77. Lubricate the non-adjusting slide pucks and slide

track on the upper slide plate with molydisulfide
grease.
78. Install the upper slide plate over the front slide pucks
on the swivel assembly.
RCPH10TLB864ABL 51
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79. Lift the slide control and slide the upper slide plate
into position on the swivel assembly.
RCPH10TLB863ABL 52
80. Install and tighten the two Allen head bolts in the two
slide pucks on the right side of the upper slide plate.
NOTE: Slide the upper plate fore or aft until the bolt holes
in the side rail are visible.
RCPH10TLB861ABL 53
81. Install the seat stop on the upper slide plate.
RCPH10TLB860ABL 54
82. Install and tighten the two Allen head bolts in the seat
stop.
RCPH10TLB859ABL 55
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83. Install the armrests.

A. Place the armrest in the hole on the seat.
RCPH10TLB856ABL 56
84. Instal the armrests.

B. Push in on the armrest as shown.
C. Rotate the armrest clockwise past the upper
stop.
RCPH10TLB857ABL 57
85. Connect the cable assembly to the lumbar support

assembly.
RCPH10TLB923ABL 58
86. Install and tighten the mounting screw (1) in the hous-
ing for the lumbar support adjustment knob.
87. Install the lumbar support adjustment knob (2) on the
housing.
88. Push the knob onto the housing until the plastic re-
tainer is locked in position.
RCPH10TLB924ABL 59
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89. Place the backrest cover in position on the seat top.

90. Install the plastic clips in the mounting holes of the
backrest cover.
91. Use a soft hammer to drive the plastic clips into the
mounting holes of the seat top.
RCPH10TLB921ABL 60
92. Place the seat assembly into position on the seat

base.
93. Install and tighten the four bolts.
RCPH10TLB858ABL 61
94. After the seat has been assembled, adjust the slide
pucks to the desired lateral movement of the seat.
RCPH10TLB862ABL 62
95. Check the seat for proper operation.
Next operation:
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Index

Pneumatically-adjusted operator seat - Assemble - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Pneumatically-adjusted operator seat - Assemble - Mechanical suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Pneumatically-adjusted operator seat - Assemble - Pedestal seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Pneumatically-adjusted operator seat - Disassemble - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Pneumatically-adjusted operator seat - Disassemble - Mechanical suspension seat . . . . . . . . . . . . . . . . . . . . . . . . 19
Pneumatically-adjusted operator seat - Disassemble - Pedestal seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Pneumatically-adjusted operator seat - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Pneumatically-adjusted operator seat - Inspect - Air suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Pneumatically-adjusted operator seat - Inspect - Mechanical suspension seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Pneumatically-adjusted operator seat - Inspect - Pedestal seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pneumatically-adjusted operator seat - Replace - Pivot safety switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Seat pneumatic lift system - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Cab - 150
580N
580SN WT
580SN
590SN
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Contents
Cab - 150
TECHNICAL DATA
Cab
Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SERVICE
Cab
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Remove Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Install Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
47365539 08/07/2012
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Platform, cab, bodywork, and decals - Cab
Cab - Torque
Cab and ROPS canopy
Mounting bolts: 298 - 358 N·m (220 - 264 lb ft)
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Cab - Inspect
DANGER
Crushing hazard!
Do not change the Roll Over Protective Structure (ROPS) in any way. Unauthorized changes such as
welding, drilling, or cutting will weaken the ROPS and decrease your protection. Have an authorized
dealer replace the ROPS if damage of any kind occurs. DO NOT TRY TO REPAIR THE ROPS.
D0037A
After an accident, fire, tip over, or roll over, have a qualified

technician inspect and replace cab or ROPS canopy and
other protective structure components (such as the seat
belt), before returning the machine to operation.
1. Replace the cab or ROPS canopy.
2. Inspect the mounting and suspension for the cab
or ROPS canopy, the operator's seat and suspen-
sion, the seat belt and mounting components, and
the wiring for damage. Replace damaged parts.
3. Tighten all bolts and mounted equipment to specifi-
cations.
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Cab - Remove Cab

Prior operation:
Prior operation:
Radiator - Remove (10.400) Steps 1 through 4 and step 10.
Refer to illustration Roll Over Protective Structure

(ROPS) frame - Exploded view (90.114).
1. Lower backhoe and stabilizers to the ground.
RCPH11TLB063AAM 1
2. Raise the loader in the full upright position and en-

gage the lockout.
RCPH11TLB001AAM 2
RCPH11TLB064AAM 3
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4. Remove four screws from the right hand and left

hand side of the front floor mat.
RCPH11TLB065AAM 4
5. Remove front floor mat.
RCPH11TLB066AAM 5
6. Remove vent louver.
RCPH11TLB067AAM 6
7. Remove louver mounting plate.
RCPH11TLB068AAM 7
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8. Remove the screw from the loader control boot.
RCPH11TLB069AAM 8
9. Pull the loader boot up over the control stick.
RCPH11TLB070AAM 9
10. Remove the snap ring and remove the boot.
RCPH11TLB075AAL 10
11. Remove the loader control console cover.
RCPH11TLB071AAM 11
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12. Remove floor plate hardware.
RCPH11TLB072AAM 12
13. Remove both floor plates.
RCPH11TLB073AAM 13
14. Disconnect electrical connection 1.
RCPH11TLB074AAM 14
15. Disconnect electrical connection 2.
RCPH11TLB074AAM 15
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16. Disconnect the main harness connector.
RCPH11TLB075AAM 16
17. Identify, tag and remove the bolts securing the loader
control rods.
RCPH11TLB076AAM 17
18. Remove the screws from the backhoe control boot

and raise the boot.
RCPH11TLB077AAM 18
19. Remove the screws from the backhoe control tower

cover.
RCPH11TLB078AAM 19
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20. If equipped, remove the auxiliary control stick cover.
RCPH11TLB079AAM 20
21. Remove the backhoe control tower covers.
RCPH11TLB080AAM 21
22. If equipped, remove the rear floor mat.
RCPH11TLB081AAM 22
23. Remove the bolts on the rear floor plate. Remove

the floor plate.
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24. Remove the bolts on the front floor plate. Remove

the floor plate.
RCPH11TLB084AAM 25
25. Disconnect the power shift electrical connector.
RCPH11TLB009AAL 26
26. Disconnect brake tubes. Cap all open lines.
RCPH11TLB085AAM 27
27. Label and disconnect heater hoses.
RCPH11TLB085AAM 28
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28. Disconnect the A/C lines. Cap all open lines.
RCPH11TLB086AAM 29
29. Remove the cotter pin and clevis pin from the boom
lock lever.
RCPH11TLB087AAM 30
30. Remove the bolt securing the boom lock cable to the
latch.
RCPH11TLB088AAM 31
31. Disconnect the air restriction indicator.
RCPH11TLB089AAM 32
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32. Remove air cleaner to turbo tube. Cap all open ports.
RCPH11TLB036AAM 33
33. Remove aspirator tube.
RCPH11TLB037AAM 34
34. Remove crank case vent.
RCPH11TLB038AAM 35
35. Remove fixed hood hardware.
RCPH11TLB039AAM 36
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36. Lift fixed hood and remove washer hose.
RCPH11TLB040AAM 37
37. Remove fixed hood with air cleaner together. A lifting

device may be needed to remove hood.
RCPH10TLB031AAL 38
38. Remove the bolts securing the rubber insulator to the

firewall. Remove the rubber.
RCPH11TLB090AAM 39
39. Disconnect the brake tubes from the master cylinder.

Cap all open lines.
RCPH11TLB091AAM 40
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40. Remove steering valve mount hardware and steering

valve.
RCPH11TLB092AAM 41
41. Remove rear cab mount hardware.
RCPH11TLB093AAM 42
42. Remove front cab mount hardware.
RCPH11TLB094AAM 43
43. Remove the right hand rear wheel well inner mud
flap.
RCPH11TLB095AAM 44
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RCPH11TLB096AAM 45
45. Slowly raise and remove the cab. When lifting the
cab, make sure all cables or hoses still connected to
the cab are free from the machine.
RCPH11TLB097AAM 46
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Cab - Install Cab

Refer to illustration Roll Over Protective Structure
(ROPS) frame - Exploded view (90.114).
1. Slowly lower the cab onto the machine. When lower-
ing the cab, make sure all cables or hoses connected
to the cab will not be crushed as the cab is lowered
onto the chassis.
RCPH10TLB624AAL 1
RCPH11TLB096AAM 2
3. Install the right hand rear wheel well inner mud flap.
RCPH11TLB095AAM 3
4. Install front cab mount hardware.
RCPH11TLB094AAM 4
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5. Install rear cab mount hardware.
RCPH11TLB093AAM 5
6. Install steering valve mount hardware and steering

valve.
RCPH11TLB092AAM 6
7. Remove caps. Connect the brake tubes to the mas-

ter cylinder.
RCPH11TLB091AAM 7
8. Place the rubber on the firewall. Secure rubber to

firewall using the existing bolts.
RCPH11TLB090AAM 8
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9. Slowly lower the fixed hood with air cleaner together

into place.
RCPH10TLB031AAL 9
10. Install fixed hood hardware.
RCPH11TLB039AAM 10
11. Reconnect the washer hose.
RCPH11TLB040AAM 11
12. Connect crank case vent.
RCPH11TLB038AAM 12
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13. Connect aspirator tube.
RCPH11TLB037AAM 13
14. Install the air cleaner to turbo tube.
RCPH11TLB036AAM 14
15. Connect the air restriction indicator.
RCPH11TLB089AAM 15
16. Install the bolt securing the boom lock cable to the
latch.
RCPH11TLB088AAM 16
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17. Install the cotter pin and clevis pin into the boom lock
lever.
RCPH11TLB087AAM 17
18. Reconnect the A/C lines.
RCPH11TLB086AAM 18
19. Connect heater hoses.
RCPH11TLB085AAM 19
20. Connect brake tubes.
RCPH11TLB085AAM 20
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21. Connect the power shift electrical connector.
RCPH11TLB009AAL 21
22. Lower the front floor plate into place. Install the bolts.
RCPH11TLB084AAM 22
23. Lower the rear floor plate into place. Install the bolts
into the rear floor plate.
24. If equipped, install the rear floor mat.
RCPH11TLB081AAM 25
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25. Install the backhoe control tower covers.
RCPH11TLB080AAM 26
26. If equipped, install the auxiliary control stick cover.
RCPH11TLB079AAM 27
27. Install the screws into the backhoe control tower

cover.
RCPH11TLB078AAM 28
28. Slide the backhoe control boot into place. Fasten the
boot to the console with the existing screws.
RCPH11TLB077AAM 29
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29. Reconnect the loader control rods.
RCPH11TLB076AAM 30
30. Connect the main harness connector.
RCPH11TLB075AAM 31
31. Connect electrical connection 2.
RCPH11TLB074AAM 32
32. Connect electrical connection 1.
RCPH11TLB074AAM 33
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33. Lower the floor plates into place.
RCPH11TLB073AAM 34
34. Secure the floor plate to the floor with the existing
hardware.
RCPH11TLB072AAM 35
35. Install the loader control console cover.
RCPH11TLB071AAM 36
36. Slide the boot over the control stick. Install the snap
ring.
RCPH11TLB075AAL 37
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37. Pull the loader boot down over the control stick.
RCPH11TLB070AAM 38
38. Attach the boot to the console using the existing

hardware.
RCPH11TLB069AAM 39
39. Install the louver mounting plate.
RCPH11TLB068AAM 40
40. Install the vent louver.
RCPH11TLB067AAM 41
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41. Install the front floor mat.
RCPH11TLB066AAM 42
42. Secure the front floor mat to the floor using the four
screws.
RCPH11TLB065AAM 43
Next operation:
Next operation:
Battery - Connect (55.302)
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Index
Cab - 150
Cab - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cab - Install Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cab - Remove Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cab - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cab interior - 151
580N
580SN WT
580SN
590SN
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Contents
Cab interior - 151
SERVICE
Seat restraints
Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Platform, cab, bodywork, and decals - Cab interior
Seat restraints - Install

1. Install the retractable belt strap on the right-hand side
of the seat.
A. Place at 45 ° +/- 5 ° angle.
RCPH10TLB753ABL 1
B. Secure using the spacer (1) and the bolt (2).

C. Torque the bolt to 94 - 106 N·m (69 - 78 lb ft).
RCPH10TLB439AAF 2
2. Install the buckle/latch mechanism on the left-side of

the seat.
A. Use the spacer (1), washers (2), bracket (3),
and bolt (4).
B. Torque the bolt to 94 - 106 N·m (69 - 78 lb ft).
RCPH10TLB440AAF 3
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Index
Cab interior - 151

Seat restraints - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
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Cab doors and hatches - 154
580N
580SN WT
580SN
590SN
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Contents
FUNCTIONAL DATA
Cab doors and hatches

Exploded view Rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Exploded view - Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exploded view - Side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE
Cab doors and hatches

Remove - Rear window - top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Install - Rear window - top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Remove - Rear window - middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install - Rear window - middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Remove - Rear window - bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Install - Rear window - bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

47365539 08/07/2012
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CONSUMABLES INDEX
Consumable IU PAGE
Loctite® 243 Cab doors and hatches - Install - Rear window - middle 90.154 / 18
47365539 08/07/2012
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Platform, cab, bodywork, and decals - Cab doors and hatches
Cab doors and hatches - Exploded view Rear window
RCPH10TLB001GAD 1
(A) Top latch assembly (right-hand and left-hand sides)

(B) Middle latch assembly (right-hand and left-hand sides)
(1) Rear window frame
(2) Flocked channel seal (right-hand and left hand side)
(3) Rubber block window stop
(4) Top window
(5) Middle window
(6) Bottom window
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47365539 08/07/2012
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Cab doors and hatches - Exploded view - Door

Machines equipped with two doors have similar components however most of the components will not be
interchangeable because of the curvature of the cab design. The exploded view shown is for the standard
left-hand side door.
(1) Door gasket
(2) Window latch bracket
(3) Door frame
(4) Hinge pin and circlip
(5) Window latch
(6) Window hinge hardware with rubber washer
(7) Window gasket
(8) Window
(9) Window hinge
(10) Window hinge mounting plate
(11) Button latch
(12) Door handle with gasket
(13) Door latch cover
(14) Gas spring stud
(15) Door latch assembly
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RCPH10TLB001HAD 1
47365539 08/07/2012
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Cab doors and hatches - Exploded view - Side window

Rear side window components (both sides)
The curvature of the rear side window creates a distinct difference between the left and right-hand side windows
which is not interchangeable. However, the component layout is the same for both sides.
(1) Latch bracket
(2) Latch locking mechanism
(3) Hinge hardware
(4) Gasket
(5) Window glass
(6) Rubber door stop
(7) Hinge with rubber gasket
(8) Hinge hardware
(9) Button latch
47365539 08/07/2012
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RCPH10TLB003GAD 1
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Front side window components (no door)

Machines equipped with only one door will have a similar front side windows with the exception of a few
components only applicable to the door version.
(1) Hinge pin with circlip
(2) Hinge hardware with rubber washers
(3) Hinge bracket
(4) Hinge bracket hardware
(5) Latch bracket
(6) Latch locking mechanism
(7) Gasket
(8) Window glass
(9) Button latch
(10) Hinge with rubber gasket
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RCPH10TLB004GAD 2
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Cab doors and hatches - Remove - Rear window - top

All instructions are written viewing the machine from the rear.
It is recommended that two people work on the following procedure.
1. Park the machine on a level surface. Lower all at-

tachments to the ground. Apply the parking brake.
2. Raise the top window to the closed position.
3. Remove the lower flocked channel seal (1) from the
left-hand side of the frame.
RCPH10TLB001CAD 1
4. From inside the cab, have a helper lower the middle

window into the lowest position and the top window
one setting above the middle window.
5. Have the helper hold the top window in place.
6. Remove the left-hand side latch assembly (1) from
the window.
RCPH10TLB126AAF 2
47365539 08/07/2012
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7. Guide the top window horizontally into the left chan-

nel until the right-hand side of the top window (1) is
exposed.
RCPH10TLB001AAD 3
NOTICE: Forcing the window to bend during removal may cause damage to the window.
8. Remove the top window from the frame.
9. If the top window is not being replaced, install the
previously removed flocked channel seal into the left
channel.
Next operation:
Cab doors and hatches - Remove - Rear window - middle (90.154)
47365539 08/07/2012
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Cab doors and hatches - Install - Rear window - top

All instructions are written viewing the machine's rear window from the rear.
Prior operation:
Cab doors and hatches - Remove - Rear window - top (90.154)
NOTE: Replace worn or damaged seals, gaskets and latch components.

1. Install the seal trim (1) across the bottom of the top
window.
RCPH10TLB004AAD 1
2. Secure the top right-hand latch assembly to the right

side of the top window.
RCPH10TLB006AAD 2
NOTE: The right-hand latch rubber bumper (1) must be above the middle window.
NOTICE: Forcing the window to bend during installation may cause damage to the window.
3. Guide the top window horizontally into the left chan-
nel where the flocked channel seal was previously
removed from.
RCPH10TLB001AAD 3
47365539 08/07/2012
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4. Slide the top window into the right-hand side channel.

Have a helper hold the top window in place while the
latch assembly is installed.
5. Secure the top left-hand latch assembly (1) to the top
window.
RCPH10TLB126AAF 4
6. Slide the top window up until it locks into the closed

position.
7. Install the flocked channel seal (1) into the frame.
RCPH10TLB001CAD 5
47365539 08/07/2012
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Cab doors and hatches - Remove - Rear window - middle


2. Place the top window (1) and the middle window (2)
in the highest position.
3. Remove the lower flocked channel seal (3) from the
left-hand side of the frame rail the middle window is
in.
RCPH10TLB001CAD 1
4. Have a helper lower the middle window until the left-

hand latch assembly (1) is accessible from the out-
side.
CAUTION
Burn hazard!
Always wear heat-resistant protective gloves
when handling heated parts.
Failure to comply could result in minor or mod-
erate injury.
C0047A
NOTE: If there is difficulty removing the latch assembly

Permabond F246 was used during the installation, you will
need to apply heat to the adhesive to remove the latch.
Use a heat gun that does not exceed 538 °C (1000 °F) at
the tip. Apply heat to the outside latch mounting plate, take
care not to damage the cab.
5. Have the helper support the window. Remove the
left-hand latch assembly from the middle window.
RCPH10TLB002CAD 2
47365539 08/07/2012
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6. Lower the window until even with the open channel

area. Guide the middle window horizontally into the
left channel until the right-hand side of the window
(1) is exposed.
RCPH10TLB003CAD 3
7. Remove the middle window from the frame.
Next operation:
Cab doors and hatches - Install (90.154)
47365539 08/07/2012
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Cab doors and hatches - Install - Rear window - middle

Prior operation:
Cab doors and hatches - Remove (90.154)
NOTE: Replace worn or damaged seals, gaskets and latch components.

1. Install a seal across the bottom of the middle window.
RCPH10TLB009AAD 1
NOTE: Do not get Permabond F246 adhesive into the slot on the latch mounting surface.
NOTICE: The latch parts must be completely assembled within 3 min of applying the Permabond F246 adhesive.
NOTICE: Do not overtighten Allen head screws otherwise damage to the glass may occur.
2. Secure the right-hand latch assembly to the middle
window. Use the following procedure to secure the
latch:
A. Clean the mounting surface on the middle win-
dow with a commercial glass cleaner.
B. Clean the mounting surface on the latch as-
sembly with alcohol.
C. Apply a thin film of the initiator to the mounting
surface on the middle window.
D. Apply a bead of Permabond F246 adhesive to
the latch mounting surface.
E. Align the gasket and plate on the outside of the
window. The protrusions on the gasket fit into
the holes on the window.
F. Assemble the latch on the inside of the window.
G. Apply LOCTITE® 243 to the threads on the Allen RCPH10TLB010AAD 2
head screws.
Install and tighten the Allen head screws to a
torque of 0.56 - 1.13 N·m (5 - 10 lb in).
47365539 08/07/2012
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3. Slide the middle window horizontally into the left

channel where the flocked channel seal was previ-
ously removed from the frame until the right side of
the window (1) can be moved into the channel on
the right side of the frame.
RCPH10TLB003CAD 3
4. Slide the middle window to the right and up until the

middle window is out of the way. Have a person on
the inside of the machine hold the middle window in
position.
RCPH10TLB003CAD 4
47365539 08/07/2012
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5. Install the left-hand side middle latch assembly (1)

and raise the window to it's highest position. Follow
the previous procedure (Step 2) for latch assembly.
6. Install the previously removed flocking channel seal
(2) into the frame.
RCPH10TLB002CAD 5
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Cab doors and hatches - Remove - Rear window - bottom

The following procedure is performed from inside the cab.

2. Remove the upper flocked channel seal from the left
side of the frame rail that the bottom window is in.
RCPH10TLB349AAF 1
3. Remove the rubber blocks located on both sides of

the frame directly above the bottom window.
RCPH10TLB342AAF 2
4. Move the top and middle window into the highest

positions.
5. Raise the bottom window until the window is in the
area the flocked channel seal was removed from.
6. Guide the bottom window into the left channel until
the right side of the window is exposed.
7. Move the right side of the bottom window away from
the frame until the window can be removed from the
frame.
8. Remove the bottom window.
9. If the bottom window is not being replaced. Make
sure the flocked channel seal is installed in the left
channel.
Next operation:
Cab doors and hatches - Install (90.154)
47365539 08/07/2012
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Cab doors and hatches - Install - Rear window - bottom

Prior operation:
Cab doors and hatches - Remove (90.154)
1. Install a new seal on the bottom of the bottom window

as required.
RCPH10TLB012AAD 1
2. Place the top and middle windows in their highest

position.
3. Slide the bottom window into the left channel where
the flocked channel seal was removed from the
frame. When the right side of the bottom window
clears the inside of the frame guide the window into
the right side channel of the frame.
4. Slide the bottom window to the right and down until
the bottom window is in position.
5. Install the flocked channel seal in the frame.
6. Install the rubber blocks on both sides above the bot-
tom window.
47365539 08/07/2012
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Index

Cab doors and hatches - Exploded view - Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Cab doors and hatches - Exploded view - Side window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Cab doors and hatches - Exploded view Rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cab doors and hatches - Install - Rear window - bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cab doors and hatches - Install - Rear window - middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Cab doors and hatches - Install - Rear window - top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cab doors and hatches - Remove - Rear window - bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cab doors and hatches - Remove - Rear window - middle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cab doors and hatches - Remove - Rear window - top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
47365539 08/07/2012
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PRINTED IN U.S.A.
47365539 08/07/2012
EN
SCHEMAS INDEX
IU PAGE
Wire connectors - Component Diagram 00 – Connectors X-001 through X-009 55.100 / 239
Wire connectors - Component diagram 01 – Connectors X-010 through X-019 55.100 / 250
Wire harnesses - Electrical schematic frame 01 Power Distribution/ Charging System, 55.100 / 12
Wire harnesses - Electrical schematic frame 02 Starting System, Power Shuttle 55.100 / 20
Wire harnesses - Electrical schematic frame 02 Starting System, Power Shuttle 55.100 / 22
Wire harnesses - Electrical schematic frame 02 Starting System, Powershift transmission 55.100 / 24
with options
Wire harnesses - Electrical schematic frame 02 Starting System, Powershift transmission 55.100 / 26
without options
Wire harnesses - Electrical schematic frame 03 Grounding, Power Shuttle transmission 55.100 / 28
with options
Wire harnesses - Electrical schematic frame 03 Grounding, Power Shuttle transmission 55.100 / 30
without options
Wire harnesses - Electrical schematic frame 03 Grounding, Powershift transmission with 55.100 / 32
options
Wire harnesses - Electrical schematic frame 03 Grounding, Powershift transmission 55.100 / 34
without options
Wire harnesses - Electrical schematic frame 04 Engine Control, Power Shuttle 55.100 / 36
47365539 08/07/2012
IU PAGE
Wire harnesses - Electrical schematic frame 04 Engine Control, Powershift transmission 55.100 / 40
with options
without options
with options
without options
Wire harnesses - Electrical schematic frame 06 Drives, Power Shuttle transmission with 55.100 / 52
options
Wire harnesses - Electrical schematic frame 06 Drives, Power Shuttle transmission 55.100 / 54
without options
Wire harnesses - Electrical schematic frame 06 Powershift Transmission Inputs, 55.100 / 56
Wire harnesses - Electrical schematic frame 06 Powershift Transmission Inputs, 55.100 / 58
Wire harnesses - Electrical schematic frame 07 Hydraulics, Power Shuttle transmission 55.100 / 60
with options
Wire harnesses - Electrical schematic frame 07 Hydraulics, Power Shuttle transmission 55.100 / 62
without options
Wire harnesses - Electrical schematic frame 07 Hydraulics, Powershift transmission with 55.100 / 64
options
Wire harnesses - Electrical schematic frame 07 Hydraulics, Powershift transmission 55.100 / 66
without options
Wire harnesses - Electrical schematic frame 08 Pilot Controls, Power Shuttle transmission 55.100 / 68
with options
Wire harnesses - Electrical schematic frame 08 Pilot Controls, Power Shuttle transmission 55.100 / 70
without options
Wire harnesses - Electrical schematic frame 08 Pilot Controls, Powershift transmission 55.100 / 72
with options
Wire harnesses - Electrical schematic frame 08 Pilot Controls, Powershift transmission 55.100 / 74
without options
Wire harnesses - Electrical schematic frame 09 Front Exterior Lights, Power Shuttle 55.100 / 76
Wire harnesses - Electrical schematic frame 09 Front Exterior Lights, Power Shuttle 55.100 / 78
Wire harnesses - Electrical schematic frame 09 Front Exterior Lights, Powershift 55.100 / 80
Wire harnesses - Electrical schematic frame 09 Front Exterior Lights, Powershift 55.100 / 82
Wire harnesses - Electrical schematic frame 10 Interior Lighting, Power Shuttle 55.100 / 84
Wire harnesses - Electrical schematic frame 10 Interior Lighting, Power Shuttle 55.100 / 86
Wire harnesses - Electrical schematic frame 10 Interior Lighting, Powershift transmission 55.100 / 88
with options
Wire harnesses - Electrical schematic frame 10 Interior Lighting, Powershift transmission 55.100 / 90
without options
Wire harnesses - Electrical schematic frame 11 Windshield Wipers, Powershift 55.100 / 96
Wire harnesses - Electrical schematic frame 11 Windshield Wipers, Powershift 55.100 / 98
Wire harnesses - Electrical schematic frame 11 Wipers and Washers, Power Shuttle 55.100 / 92
47365539 08/07/2012
IU PAGE
Wire harnesses - Electrical schematic frame 11 Wipers and Washers, Power Shuttle 55.100 / 94
Wire harnesses - Electrical schematic frame 12 Instrument Cluster, Power Shuttle 55.100 / 100
Wire harnesses - Electrical schematic frame 12 Instrument Cluster, Power Shuttle 55.100 / 102
Wire harnesses - Electrical schematic frame 12 Instrument Cluster, Powershift 55.100 / 104
Wire harnesses - Electrical schematic frame 12 Instrument Cluster, Powershift 55.100 / 106
Wire harnesses - Electrical schematic frame 13 Power Points, Power Shuttle transmission 55.100 / 108
with options
Wire harnesses - Electrical schematic frame 13 Power Points, Power Shuttle transmission 55.100 / 110
without options
Wire harnesses - Electrical schematic frame 13 Power Points, Powershift transmission 55.100 / 112
with options
Wire harnesses - Electrical schematic frame 13 Power Points, Powershift transmission 55.100 / 114
without options
Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Power Shuttle 55.100 / 116
Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Power Shuttle 55.100 / 118
Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Powershift 55.100 / 120
Wire harnesses - Electrical schematic frame 14 SAHR Park Brake, Powershift transmission 55.100 / 122
without options
Wire harnesses - Electrical schematic frame 15 HVAC, Power Shuttle transmission with 55.100 / 124
options
Wire harnesses - Electrical schematic frame 15 HVAC, Power Shuttle transmission 55.100 / 126
without options
Wire harnesses - Electrical schematic frame 15 HVAC, Powershift transmission with 55.100 / 128
options
Wire harnesses - Electrical schematic frame 15 HVAC, Powershift transmission without 55.100 / 130
options
Wire harnesses - Electrical schematic frame 16 Radio, Power Shuttle transmission with 55.100 / 132
options
Wire harnesses - Electrical schematic frame 16 Radio, Power Shuttle transmission without 55.100 / 134
options
Wire harnesses - Electrical schematic frame 16 Radio, Powershift transmission with 55.100 / 136
options
Wire harnesses - Electrical schematic frame 16 Radio, Powershift transmission without 55.100 / 138
options
Wire harnesses - Electrical schematic frame 17 Rear Exterior Lights, Powershift 55.100 / 144
Wire harnesses - Electrical schematic frame 17 Rear Lights Exterior, Power Shuttle 55.100 / 140
Wire harnesses - Electrical schematic frame 17 Rear Lights Exterior, Power Shuttle 55.100 / 142
Wire harnesses - Electrical schematic frame 17 Rear Lights Exterior, Powershift 55.100 / 146
Wire harnesses - Electrical schematic frame 18 Options, Power Shuttle transmission 55.100 / 148
with options
Wire harnesses - Electrical schematic frame 18 Options, Power Shuttle transmission 55.100 / 150
without options
Wire harnesses - Electrical schematic frame 18 Options, Powershift Transmission with 55.100 / 152
options
Wire harnesses - Electrical schematic frame 18 Options, Powershift transmission without 55.100 / 154
options
Wire harnesses - Electrical schematic frame 19 Horn, Power Shuttle transmission with 55.100 / 156
options
47365539 08/07/2012
IU PAGE
Wire harnesses - Electrical schematic frame 19 Horn, Power Shuttle transmission without 55.100 / 158
options
Wire harnesses - Electrical schematic frame 19 Horn, Powershift transmission with options 55.100 / 160
Wire harnesses - Electrical schematic frame 19 Horn, Powershift transmission without 55.100 / 162
options
Wire harnesses - Electrical schematic frame 20 Comfort Steer/ Ride Control, Power 55.100 / 164
Wire harnesses - Electrical schematic frame 20 Comfort Steer/ Ride Control, Power 55.100 / 166
Wire harnesses - Electrical schematic frame 20 Comfort Steer/ Ride Control, Powershift 55.100 / 168
Wire harnesses - Electrical schematic frame 20 Comfort Steer/ Ride Control, Powershift 55.100 / 170
Wire harnesses - Electrical schematic frame 21 Canopy Exterior Lights, Powershift 55.100 / 176
Wire harnesses - Electrical schematic frame 21 Canopy Exterior Lights, Powershift 55.100 / 178
Wire harnesses - Electrical schematic frame 21 Hydraulic Options Powerlift, Power Shuttle 55.100 / 172
Wire harnesses - Electrical schematic frame 21 Hydraulic Options Powerlift, Power Shuttle 55.100 / 174
Wire harnesses - Electrical schematic frame 22 Pilot Control Inputs, Power Shuttle 55.100 / 182
Wire harnesses - Electrical schematic frame 22 Pilot Controls Inputs, Power Shuttle 55.100 / 180
Wire harnesses - Electrical schematic frame 22 Powershift Transmission Jumper Harness, 55.100 / 184
Wire harnesses - Electrical schematic frame 22 Powershift Transmission Jumper Harness, 55.100 / 186
Wire harnesses - Electrical schematic frame 23 Combo/ Aux/ Uni Hydraulics, Power 55.100 / 188
Wire harnesses - Electrical schematic frame 23 Combo/ Aux/ Uni Hydraulics, Power 55.100 / 190
Wire harnesses - Electrical schematic frame 23 TRAX Powershift Controller 55.100 / 194
Wire harnesses - Electrical schematic frame 23 TRAX Powershift Controller, Powershift 55.100 / 192
Wire harnesses - Electrical schematic frame 24 Canopy Exterior Lights, Power Shuttle 55.100 / 196
Wire harnesses - Electrical schematic frame 24 Canopy Exterior Lights, Power Shuttle 55.100 / 198
Wire harnesses - Electrical schematic frame 24 Hydraulic PowerLift, Powershift 55.100 / 202
Wire harnesses - Electrical schematic frame 24 Hydraulic PowerLift, Powershift 55.100 / 200
transmissions with options
Wire harnesses - Electrical schematic frame 25 Can Bus/ Diagnostics, Power Shuttle 55.100 / 204
Wire harnesses - Electrical schematic frame 25 Can Bus/ Diagnostics, Power Shuttle 55.100 / 206
Wire harnesses - Electrical schematic frame 25 Combo Hydraulics, Powershift 55.100 / 208
Wire harnesses - Electrical schematic frame 25 Combo Hydraulics, Powershift 55.100 / 210
Wire harnesses - Electrical schematic frame 26 Pilot Control Inputs, Powershift 55.100 / 216
Wire harnesses - Electrical schematic frame 26 Pilot Control Inputs, Powershift 55.100 / 218
Wire harnesses - Electrical schematic frame 26 Telematics, Power Shuttle transmission 55.100 / 212
with options
Wire harnesses - Electrical schematic frame 26 Telematics, Power Shuttle transmission 55.100 / 214
without options
47365539 08/07/2012
IU PAGE
Wire harnesses - Electrical schematic frame 27 2WD Ride Control Jumper, Power Shuttle 55.100 / 220
Wire harnesses - Electrical schematic frame 27 Accessory Jumpers, Power Shuttle 55.100 / 222
Wire harnesses - Electrical schematic frame 27 Accessory Jumpers, Powershift 55.100 / 224
Wire harnesses - Electrical schematic frame 27 Accessory Jumpers, Powershift 55.100 / 226
Wire harnesses - Electrical schematic frame 28 Accessory Jumpers, Power Shuttle 55.100 / 228
Wire harnesses - Electrical schematic frame 28 CAN Bus/ Diagnostics, Powershift 55.100 / 230
Wire harnesses - Electrical schematic frame 28 CAN Bus/ Diagnostics, Powershift 55.100 / 232
Wire harnesses - Electrical schematic frame 29 Telematics, Powershift transmission with 55.100 / 234
options
Wire harnesses - Electrical schematic frame 29 Telematics, Powershift transmission 55.100 / 236
without options
47365539 08/07/2012
SPECIAL TOOL INDEX
Genuine IU PAGE
CAS1716-3 [Driver Handle] Powered rear axle - Special tools - 580N and 580SN only 27.100 / 4
CAS1660 [Hydraulic Ram Boom cylinder - Assemble - Boom cylinder 35.736 / 12
Seal Installer / Remover]
CAS1660 [Hydraulic Ram Dipper cylinder - Assemble - Dipper cylinder 35.737 / 13
Seal Installer / Remover]
CAS1456 [Gland Wrench] Swing cylinder - Disassemble - Swing cylinders 35.739 / 13
CAS1039 [Torque Multiplier] Swing cylinder - Disassemble - Swing cylinders 35.739 / 13
CAS1039 [Torque Multiplier] Swing cylinder - Assemble - Swing cylinders 35.739 / 15
CAS1039 [Torque Multiplier] Swing cylinder - Assemble - Swing cylinders 35.739 / 15
380000239 [High And Low Air conditioning - Pressure test and temperature testing 50.200 / 19
Manifold Pressure Control
Device ]
CAS10147 [Battery Capacity Battery - Test 55.302 / 6
(Load) Tester]
CAS10147 [Battery Capacity Battery - Test 55.302 / 6
(Load) Tester]
380040185 [Harness 3095-Operating With Camshaft Sensor Only - Backup Mode 55.DTC / 217
Diagnostic /Repair Kit (NEF)]
Kit IU PAGE
380001737 [Nitrogen Accumulator - Special tools - Ride control 35.300 / 3
Charging Kit with High
Pressure Regulator and hoses
complete]
380001737 [Nitrogen Accumulator - Check - Ride control 35.300 / 7
complete]
380001737 [Nitrogen Accumulator - Charging - Ride control 35.300 / 8
complete]
380001737 [Nitrogen Accumulator - Discharging - Ride control 35.300 / 9
complete]
08/07/2012
30
08/07/2012
31
PRINTED IN U.S.A.
47365539 08/07/2012
EN
580N
PILOT HYDRAULICS
RAC 84390777
GEAR PUMP SUPPLY STEERING UNIT

GEAR PUMP SUPPLY TO CONTROLS
RETURN TO TANK/SUMP
RAC 84390777S1S2
CONNECTIONS BETWEEN THE JOYSTICKS, BACKHOE VALVE AND MULTI-FUNCTION
PRERSSURE REDUCING VALVE ARE SHOWN ON SHEET 2.
580N
PILOT HYDRAULICS
RAC 84390777
GEAR PUMP SUPPLY STEERING UNIT

GEAR PUMP SUPPLY TO CONTROLS
RETURN TO TANK/SUMP
RAC 84390777S1S1
RAC 84597463
580SN (from PIN NCC564000) HYDRAULIC VVOC WITHOUT BOOST (POWERLIFT)
VARIABLE PISTON PUMP SUPPLY STEERING PRIORITY
VARIABLE PISTON PUMP SUPPLY LOADER VALVE SUPPLY
VARIABLE PISTON SUPPLY BACKHOE VALVE SUPPLY
RETURN TO TANK/SUMP
1 HPCO PUMP CONTROL

TO BE SET AT 238 BAR (3450 PSI)
COLD
START
(OPTIONAL)
71CC / 75CC
VARIABLE PISTON
PUMP
0CC MIN
DISPLACEMENT
580 SN WITHOUT
OPTIONAL POWER LIFT
RAC 84597463S1S1
RAC 84597463
580SN (from PIN NCC564000), 580SN WT (from PIN NCC567500), and
590SN (from PIN NCC568500) HYDRAULIC VVOC WITH BOOST (POWERLIFT)
RETURN TO TANK/SUMP
3
DIPPER CYLINDER SHOWN WITH DUAL ORIFICE CUSHION
FOR 590sn UNITS. 580SN AND 580SN WT UNITS ONLY
POWER LIFT VALVE HAVE SINGLE ORIFICE CUSHION.
1
1
POWERLIFT RELIEF SET
580SN AND 590SN:
250 BAR (3626 PSI)
LS IN 580SN WT: 3
261 BAR (3785 PSI)
2 2
NORMAL MODE RELIEF TO BE
DR
LS
OUT
LS G
SET TO 238 BAR (3452 PSI)
COLD
START
(OPTIONAL)
71CC / 75CC
VARIABLE PISTON
PUMP
0CC MIN
DISPLACEMENT
RAC 84597463S1S2
RAC 84597464
580SN (from PIN NCC564000), 580SN WT (from PIN NCC567500), AND
590SN (from PIN NCC568500) HYDRAULIC VVCC WITH BOOST (POWERLIFT)
VARIABLE PISTON PUMP SUPPLY STEERING UNIT
VARIABLE PISTON PUMP SUPPLY TO CONTROLS
RETURN TO TANK/SUMP
POWER RELIEF VALVE SET AT 250 BAR FOR 580SN & 590SN. DIPPER CYLINDER SHOWN WITH DUAL ORIFICE CUSHION FOR 590SN UNITS.
580SN-WT UNITS HAVE RELIEF SET AT 261 BAR. 580SN & 580SN-WT UNITS HAVE A SINGLE ORIFICE CUSHION.
NORMAL MODE RELIEF TO BE SET AT 238 BAR. CONNECTIONS BETWEEN THE JOYSTICK, BACKHOE VALVE AND MULTI-FUNCTION
PRESSURE REDUCING VALVE ARE SHOWN ON THIS PAGE.
RAC 84597464S1S1
POWER
NOTES ON PAGE 2.
580SN (from PIN NCC564000), 580SN WT (from PIN NCC567500), AND

590SN (from PIN NCC568500) HYDRAULIC VVCC WITH BOOST (POWERLIFT)
VARIABLE PISTON PUMP SUPPLY STEERING UNIT
VARIABLE PISTON PUMP SUPPLY TO CONTROLS
RAC 84597464 RETURN TO TANK/SUMP

RAC 84597464S1S2
HOUSINGS ACTUATORS
V P T
LEVER HAND FOOT TEMPERATURE
VACUUM SWITCH PRESSURE SWITCH TEMPERATURE SWITCH MOTOR LAMP
CONTACT CONFIGURATIONS
LIQUID LEVER FLOAT PRESSURE COIL DIODE
CONTACTS
MOMENTARY
S.P.S.T. S.P.D.T. D.P.S.T. D.P.D.T.
MAINTAINED
MISCELLANEOUS SYMBOLS VARIABLE RESISTOR RESISTOR
FUSE RELAY GROUND BATTERY SPL-XX

INDICATES CIRCUIT SPLICE
INDICATES CIRCUIT CONNECTION POWERLIFT
INDICATES CIRCUIT CROSSING

CIRCUIT DIAGRAM LEGENDS NOT CONNECTED
INDICATES INTERNALLY
WIRE BREAKOUT GROUNDED UNITS
WB-255 SPL WB-254

Sheet Y 0.8 255 Y 0.8 254 Sheet
Number Number
COLOR
WIREID SPLICE POWERLIFT
WIRE SIZE CIRCUIT 1
CIRCUIT 1
CIRCUIT 2 WIRE BUNDLE CIRCUIT 2
CIRCUIT 3 CIRCUIT 3
WB - WIRE BREAKOUT CIRCUIT 4 CIRCUIT 4 POWERLIFT
FB - FUSE BREAKOUT
GB - GROUND BREAKOUT
STANDARD SYMBOLS/ LEGEND POWER DISTRIBUTION/ CHARGING SYSTEM 1 STARTING SYSTEM 2 GROUNDING 3
INJECTOR
INJECTOR
A2 A2
A1 A1
INJECTOR
B2 B2
B1 B1
INJECTOR
ENGINE CONTROL 4 ENGINE CONTROL 5 DRIVES 6 HYDRAULICS 7
PILOT CONTROLS 8 FRONT EXTERIOR LIGHTS 9 INTERIOR LIGHTING 10 WIPERS AND WASHERS 11
ELECTRICAL SCHEMATIC 84582771

580N (from PIN NCC56000) with POWERSHUTTLE
580SN (from PIN NCC564000) with POWERSHUTTLE
580SN WT (from PIN NCC567500) with POWERSHUTTLE
LEGEND
INDICATES CONSTANT POWER
POWERLIFT INDICATES POWER WHEN KEY

SWITCH IS ON
INDICATES POWER WHEN KEY
SWITCH IS IN START POSITION
POWERLIFT INDICATES SWITCHED POWER
FROM CONTROL RELAY #1
INDICATES SWITCHED POWER
FROM CONTROL RELAY #2-#4
84582771S1S1
INSTRUMENT CLUSTER 12 POWER POINTS 13 SAHR PARK BRAKE 14
FUSE LOCATIONS HVAC 15 AUDIO 16 REAR EXTERIOR LIGHTS 17
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
OPTIONS 18 HORN 19 COMFORT STEER/ RIDE CONTROL 20 HYDRAULIC OPTIONS 21
PILOT CONTROL INPUTS 22 COMBO/ AUX/ UNI HYDRAULICS 23 CANOPY EXTERIOR LIGHTS 24 CAN BUS/ DIAGNOSTICS 25

580N (from PIN NCC56000) with POWERSHUTTLE
580SN WT (from PIN NCC567500) with POWERSHUTTLE
LEGEND
SWITCH IS ON
84582771S1S2
TELEMATICS 26 2WD RIDE CONTROL JUMPER 27 ACCESSORY JUMPERS 28
HOUSINGS ACTUATORS
V P T
LEVER HAND FOOT TEMPERATURE
VACUUM SWITCH PRESSURE SWITCH TEMPERATURE SWITCH MOTOR LAMP
CONTACT CONFIGURATIONS
LIQUID LEVER FLOAT PRESSURE COIL DIODE
CONTACTS
MOMENTARY
S.P.S.T. S.P.D.T. D.P.S.T. D.P.D.T.
MAINTAINED
MISCELLANEOUS SYMBOLS VARIABLE RESISTOR RESISTOR
FUSE RELAY GROUND BATTERY SPL-XX

INDICATES CIRCUIT SPLICE
INDICATES CIRCUIT CONNECTION

POWERLIFT
INDICATES CIRCUIT CROSSING
CIRCUIT DIAGRAM LEGENDS NOT CONNECTED
INDICATES INTERNALLY
WIRE BREAKOUT GROUNDED UNITS
WB-255 SPL WB-254

Sheet Y 0.8 255 Y 0.8 254 Sheet
Number Number
COLOR
POWERLIFT
WIRE ID SPLICE
WIRE SIZE CIRCUIT 1
CIRCUIT 1
CIRCUIT 2 WIRE BUNDLE CIRCUIT 2
CIRCUIT 3 CIRCUIT 3
WB - WIRE BREAKOUT CIRCUIT 4 CIRCUIT 4 POWERLIFT
FB - FUSE BREAKOUT
GB - GROUND BREAKOUT
STANDARD SYMBOLS/ LEGEND POWER DISTRIBUTION/ CHARGING SYSTEM 1 STARTING SYSTEM 2 GROUNDING 3
INJECTOR
INJECTOR
A2 A2
A1 A1
B2
INJECTOR
B2
B1 B1
INJECTOR
ENGINE CONTROL 4 ENGINE CONTROL 5 DRIVES 6 HYDRAULICS 7

580N (from PIN NCC56000) POWERSHUTTLE without options
580SN (from PIN NCC564000) POWERSHUTTLE without options
580SN WT (from PIN NCC567500) POWERSHUTTLE without options
LEGEND
POWERLIFT
SWITCH IS ON
POWERLIFT
84582772S1S1
INSTRUMENT CLUSTER 12 POWER POINTS 13 SAHR PARK BRAKE 14
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
OPTIONS 18 HORN 19 COMFORT STEER/ RIDE CONTROL 20 HYDRAULIC OPTIONS 21
PILOT CONTROL INPUTS 22 COMBO/ AUX/ UNI HYDRAULICS 23 CANOPY EXTERIOR LIGHTS 24 CAN BUS/ DIAGNOSTICS 25

580N (from PIN NCC56000) POWERSHUTTLE without options
580SN WT (from PIN NCC567500) POWERSHUTTLE without options
LEGEND
SWITCH IS ON
84582772S1S2
TELEMATICS 26 ACCESSORY JUMPERS 27 28
FNR
POWERLIFT
FUSE LOCATIONS POWER DISTRIBUTION/ CHARGING SYSTEM 1 STARTING SYSTEM 2 GROUNDING 3
INJECTOR
INJECTOR
A2 A2
A1 A1
B2 B2
INJECTOR
B1 B1
INJECTOR
ENGINE CONTROL 4 ENGINE CONTROL 5 POWERSHIFT TRANSMISSION INPUTS 6 HYDRAULICS 7

580N (from PIN NCC56000) with POWERSHIFT
580SN (from PIN NCC564000) with POWERSHIFT
580SN WT (from PIN NCC567500) with POWERSHIFT
590SN (from PIN NCC568500) with POWERSHIFT
LEGEND
POWERLIFT SWITCH IS ON
POWERLIFT FROM CONTROL RELAY #1
84582774S1S1
INTRUMENT CLUSTER 12 POWER POINTS 13 SAHR PARK BRAKE 14
OPTIONS 18 HORN 19 COMFORT STEER/ RIDE CONTROL 20 CANOPY EXTERIOR LIGHTS 21
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWER SHIFT TRANSMISSION JUMPER HARNESS 22 TRAX CONTROLLER 23 POWERLIFT 24 COMBO HYDRAULICS 25
PILOT CONTROL INPUTS 26 ACCESSORY JUMPERS 27 DIAGNOSTICS/ CAN BUS 28 TELEMATICS 29

FNR
POWERLIFT
POWERLIFT
POWERLIFT
FUSE LOCATIONS POWER DISTRIBUTION/ CHARGING SYSTEM 1 STARTING SYSTEM 2 GROUNDING 3
INJECTOR
A2 A2
INJECTOR
A1 A1
B2 B2
B1 B1
INJECTOR
INJECTOR
ENGINE CONTROL 4 ENGINE CONTROL 5 POWERSHIFT TRANSMISSION INPUTS 6 HYDRAULICS 7

580N (from PIN NCC56000) POWERSHIFT without options
580SN (from PIN NCC564000) POWERSHIFT without options
580SN WT (from PIN NCC567500) POWERSHIFT without options
590SN (from PIN NCC568500) POWERSHIFT without options
LEGEND
POWERLIFT SWITCH IS ON
POWERLIFT
84582775S1S1
INTRUMENT CLUSTER 12 POWER POINTS 13 SAHR PARK BRAKE 14
OPTIONS 18 HORN 19 COMFORT STEER/ RIDE CONTROL 20 CANOPY EXTERIOR LIGHTS 21
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWERLIFT
POWER SHIFT TRANSMISSION JUMPER HARNESS 22 TRAX CONTROLLER 23 POWERLIFT 24 COMBO HYDRAULICS 25
PILOT CONTROL INPUTS 26 ACCESSORY JUMPERS 27 DIAGNOSTICS/ CAN BUS 28 TELEMATICS 29

580N MECHANICAL
RAC 84390774
LEGEND

RETURN TO TANK/SUMP
RAC 84390774S1

580sn, N, WT 590sn N t3 Serv

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SERVICE MANUAL

Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.216

Exhaust Gas Recirculation (EGR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.501

Powershift transmission internal components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.155

Front axle system ....................................................................... 25

Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.108

Non-powered front axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.400

Rear axle system........................................................................ 27

Planetary and final drives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.120

Brakes and controls .................................................................... 33

Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.202

Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.106

Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.204

Safety and main relief valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.350

Main control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.359

Stabilizer hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.703

Front loader bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.723

Excavator and backhoe hydraulic controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.726

Boom hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.736

Dipper hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.737

Excavator and backhoe bucket hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.738

Swing arm hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.739

Telescopic arm hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.740

Frames and ballasting ................................................................. 39

Hydraulic control components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.200

Cab climate control ..................................................................... 50

Electrical systems ....................................................................... 55

Harnesses and connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.100

External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.404

Warning indicators, alarms, and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.408

Cab/Platform harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.510

FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.DTC

Front loader and bucket............................................................... 82

Booms, dippers, and buckets ....................................................... 84

Platform, cab, bodywork, and decals ............................................. 90

Protections - ROPS and FOPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.114

Safety rules - Ductile iron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Battery - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Basic instructions - Fuse and relay locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Basic instructions Fuse, relay and diode icon definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Basic instructions - Diagnostic service tool port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Basic instructions - Welding on the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Cab heater - Basic instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Torque - Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Plastic and resin parts

Safety rules - Ductile iron

Basic instructions - Important notice regarding equipment servicing

Battery - Basic instructions

• Do not run the engine with the alternator wires disconnected.

2. Remove the battery cover.

3. Disconnect the negative battery cable from the neg-

Master disconnect switch (if equipped)

Basic instructions - Fuse and relay locations

Front console box

2. Remove the fuse box cover.

3. Refer to the decal on the interior side of the panel

Front console ECU fuse and relay

Fuse or relay Designation

Side console box

2. Remove the fuse box covers as needed.

3. Refer to the decal on the interior side of the panel