Case 580sr-590sr Manual

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Service
manual
580SR
580SR+
590SR
695SR
SERIES 3
580SR
580SR+
590SR
695SR
SERIES 3
Service manual
Print No. 87643852B
Print No. 87643852B
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21199
SPICER OFF-HIGHWAY
AXLE DIVISION
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TO READER
This manual has been printed for a skilful engineer
to supply necessary technical information to carry
out service operations on this machine.
CNH ITALIA S.p.A.

Technical Information
Viale delle Nazioni, 55
41100 MODENA - Italy
Read carefully this manual to collect correct information relevant to repair procedures.
For any question or remark, or in case of any error
relevant the contents of this manual, please contact:
REFERENCE
Beyond this Service Manual, also refer to documents hereunder listed:
Z Operators Manual
Z Parts Catalogue
COMPLETE HANDBOOK FOR INSTRUCTIONS

AND REPAIRS
The complete Service Manual consists of two volumes:
Z 580SR / 580SR+ / 590SR / 695SR
Service Manual for Loader backhoe
Z 580SR / 580SR+ / 590SR / 695SR
Service Manual Engine
VOLUME
The Service Manuals for Loader backhoe and Engine contain the necessary technical information to
carry out service and repair on machine and on engine, necessary tools to carry out those operations
and information on service standard, on procedures
for connection, disconnection, disassembly and assembly of parts.
The complete Service Manual which covers the
loader backhoe models 580SR / 580SR+ / 590SR /
695SR consists of the following volumes, which can
be identified through their print number as stated below:
MACHINE TYPE
PRINT NUMBER
Service Manual - Loader backhoe
580SR / 580SR+ / 590SR / 695SR
87643852B
Service Manual - Engine
580SR / 580SR+ / 590SR / 695SR
87659057A
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PREVENT ACCIDENTS
The majority of accidents and injuries which occur in industry, on the farm, at home or on the
road, are caused by the failure of some individual to follow simple and fundamental safety rules
or precautions. For this reason MOST ACCIDENTS CAN BE PREVENTED by recognizing the
real cause and taking the necessary precautions, before the accident occurs.
Regardless of the care used in design and construction of any type of equipment, there may be
conditions that cannot be completely safeguarded against, without interfering with reasonable
accessibility and efficient operation.
A careful operator and / or technician is the best insurance against accidents. The complete observance of one simple rule would prevent many thousands of serious injuries each year.
This rule is: never attempt to clean, lubricate or adjust a machine while it is in motion.
SWARNING
Before carrying out any maintenance operation, adjustment and or repair on machines equipped
with attachments, controlled hydraulically or mechanically, make sure that the attachment is lowered and safely set on the ground. If it is necessary to have the equipment partially or fully raised
to gain access to certain items, be sure the equipment is suitably supported by means other than
the hydraulic lift cylinders, cable and /or mechanical device used for controlling the equipment.
CNH ITALIA S.p.A.

Technical Information
Viale delle Nazioni, 55
41100 MODENA - Italy
All rights reserved. Reproduction of text or illustrations, in whole or in part, is strictly prohibited.
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LOADER BACKHOE MODELS

The complete range of Loader Backhoe models described in this manual are identified below:
580SR
580SR+
590SR
695SR
Powershift
Powershuttle
Stabilizer sideshift
Stabilizer center pivot
Cab
Rops
2WD
4WD
4WS
Pilot control
Mechanical control
Engine 72 kW-97 HP model

F4GE948C*601 (mechanical)

F4HE0484C*J102 (electronic)


F4HE9484C*J103 - 4WS (electronic)
Short dipper
Long dipper
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SECTION 00 - SAFETY PRECAUTIONS

SECTION 01 - MAINTENANCE
SECTION 02 - TECHNICAL SPECIFICATIONS
1. LOADER BACKHOE MODELS .................................................................................................................... 3
2. IDENTIFICATION OF MAIN COMPONENTS............................................................................................... 4
3. SPECIFICATIONS ........................................................................................................................................ 6
3.1 DIESEL ENGINE ................................................................................................................................... 6
3.2 TRANSMISSION.................................................................................................................................... 8
3.3 AXLES ................................................................................................................................................... 9
3.4 BRAKES ................................................................................................................................................ 9
3.5 STEERING........................................................................................................................................... 10
3.6 HYDRAULIC SYSTEM ........................................................................................................................ 10
3.7 FRONT COUNTERWEIGHT ............................................................................................................... 10
3.8 NOISE AND VIBRATION LEVELS ...................................................................................................... 11
3.9 BUCKETS ............................................................................................................................................ 11
3.10 TYRES ............................................................................................................................................... 12
4. DIMENSIONS AND PERFORMANCE........................................................................................................ 13
4.1 LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE ....................................................... 13
4.2 DIMENSIONS AND PERFORMANCE OF LOADER ATTACHMENT WITH FORKS.......................... 19
4.3 BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE .................................................... 20
5. BACKHOE ATTACHMENT LIFTING CAPACITY ....................................................................................... 26
6. MAXIMUM LIFTING LOADS....................................................................................................................... 29
6.1 LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE ............................................................ 29
6.2 BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE ......................................................... 30
7. SUPPLY SUMMARY TABLE ...................................................................................................................... 31
SECTION 17 - TORQUE CONVERTERS

1. POWERSHUTTLE TORQUE CONVERTER ................................................................................................ 3
1.1 DESCRIPTION AND OPERATION........................................................................................................ 3
1.2 SPECIFICATIONS ................................................................................................................................. 4
1.3 OVERHAUL ........................................................................................................................................... 4
1.4 INSPECTION ......................................................................................................................................... 4
1.5 DISASSEMBLY AND ASSEMBLY......................................................................................................... 5
1.6 STALL TEST.......................................................................................................................................... 5
1.7 FAULT FINDING.................................................................................................................................... 6
2. POWERSHIFT TORQUE CONVERTER ...................................................................................................... 7
2.2 SPECIFICATIONS ................................................................................................................................. 8
2.3 OVERHAUL ........................................................................................................................................... 8
2.4 INSPECTION ......................................................................................................................................... 9
2.6 STALL TEST........................................................................................................................................ 11
2.7 FAULT FINDING.................................................................................................................................. 12
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SECTION 21 - TRANSMISSION
1. POWERSHUTTLE TRANSMISSION TURNER MODEL COM-T4-2025.................................................... 3
1.1 SPECIFICATIONS ................................................................................................................................. 3
1.2 MOUNTING SCREW TORQUE............................................................................................................. 5
1.3 TRANSMISSION CONTROLS............................................................................................................... 6
1.4 LUBRICATION ..................................................................................................................................... 11
1.5 TRANSMISSION OIL FLOW AND SUPPLY........................................................................................ 12
1.6 TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS ....................................... 18
1.7 TRANSMISSION POWER FLOW........................................................................................................ 19
1.8 TRANSMISSION 2WD COMPONENTS .............................................................................................. 23
1.9 TRANSMISSION 4WD COMPONENTS .............................................................................................. 26
1.10 TRANSMISSION REMOVAL ............................................................................................................. 31
1.11 DISASSEMBLY AND ASSEMBLY..................................................................................................... 32
1.12 FAULT FINDING ................................................................................................................................ 90
1.13 SPECIAL TOOLS............................................................................................................................... 93
2. POWERSHIFT TRANSMISSION DANA T16000 ..................................................................................... 94
2.1 SPECIFICATIONS ............................................................................................................................... 94
2.2 CONTROLS ......................................................................................................................................... 95
2.3 LUBRICATION ................................................................................................................................... 105
2.4 PRESSURE SPECIFICATIONS AND CHECK POINTS.................................................................... 106
2.5 TRANSMISSION COOLER................................................................................................................ 108
2.6 HYDRAULIC DIAGRAM..................................................................................................................... 109
2.7 OPERATION ...................................................................................................................................... 110
2.8 POWER FLOWS................................................................................................................................ 117
2.9 GEAR AND CLUTCH LAY OUT ........................................................................................................ 132
2.10 TRANSMISSION REMOVAL AND INSTALLATION ........................................................................ 133
2.11 TRANSMISSION COMPONENTS ................................................................................................... 137
2.12 DISASSEMBLY AND ASSEMBLY................................................................................................... 155
2.13 SPECIAL TOOLS............................................................................................................................. 264
2.14 FAULT FINDING .............................................................................................................................. 265
2.15 FAULT FINDING .............................................................................................................................. 267
SECTION 25 - FRONT AXLES

1. FRONT AXLE 2WD CARRARO ................................................................................................................. 3
1.1 SPECIFICATIONS ................................................................................................................................. 3
1.3 FAULT FINDING .................................................................................................................................. 24
2. FRONT AXLE 4WD CARRARO ............................................................................................................... 26
2.1 SPECIFICATIONS ............................................................................................................................... 26
2.2 DISASSEMBLY AND ASSEMBLY....................................................................................................... 31
2.3 FAULT FINDING .................................................................................................................................. 77
3. FRONT AXLE 4WS CARRARO ............................................................................................................... 80
3.1 SPECIFICATIONS ............................................................................................................................... 80
3.3 FAULT FINDING ................................................................................................................................ 137
4. SPECIAL TOOLS...................................................................................................................................... 140
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SECTION 27 - REAR AXLE

1. REAR AXLE 2WS ......................................................................................................................................... 3
1.1 DESCRIPTION AND OPERATION....................................................................................................... 3
1.2 SPECIFICATIONS ................................................................................................................................. 6
1.4 FAULT FINDING.................................................................................................................................. 27
2. REAR AXLE 4WS CARRARO.................................................................................................................. 28
2.1 SPECIFICATIONS ............................................................................................................................... 28
2.3 FAULT FINDING.................................................................................................................................. 81
3. SPECIAL TOOLS........................................................................................................................................ 84
SECTION 33 - BRAKES SYSTEM

1. SPECIFICATIONS ........................................................................................................................................ 3
2. PARKING BRAKE......................................................................................................................................... 6
2.1 PARKING BRAKE ADJUSTMENT ........................................................................................................ 7
3. BRAKE CYLINDERS .................................................................................................................................... 8
4. OIL BRAKE TANK ...................................................................................................................................... 13
5. BLEEDING PROCEDURE.......................................................................................................................... 13
SECTION 35 - HYDRAULIC SYSTEM

1. HYDRAULIC DIAGRAMS ............................................................................................................................. 3
1.1 HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS................................................. 3
1.2 HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS .............................................................. 5
1.5 HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS .................................................... 11
2. HYDRAULIC PUMP.................................................................................................................................... 13
2.1 DESCRIPTION AND OPERATION...................................................................................................... 13
2.2 SPECIFICATIONS ............................................................................................................................... 13
2.3 LOAD SENSING VALVE ..................................................................................................................... 16
2.4 REMOVAL ........................................................................................................................................... 18
2.5 COMPONENTS ................................................................................................................................... 19
3. CONTROL VALVES ................................................................................................................................... 24
3.1 CONTROL VALVES REXROTH (MECHANICAL MODELS) ............................................................ 24
3.2 REXROTH CONTROL VALVES (PILOT MODELS) ......................................................................... 40
3.3 SOLENOID VALVE FOR PILOTING THE BACKHOE CONTROL VALVE
(WITH HYDRAULIC CONTROL) .......................................................................................................... 49
3.4 RELIEF VALVES ................................................................................................................................. 52
3.5 ACCUMULATOR GLIDE RIDE PARKER.......................................................................................... 60
4. HYDRAULIC SWING SYSTEM .................................................................................................................. 63
4.2 HYDRAULIC OIL FLOW ...................................................................................................................... 64
5. HYDRAULIC CYLINDERS.......................................................................................................................... 66
5.1 LOADER ATTACHMENT BOOM CYLINDER ..................................................................................... 67
5.2 LOADER BUCKET CYLINDER ........................................................................................................... 72
5.3 4X1 LOADER BUCKET CYLINDER .................................................................................................... 76
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5.4 BACKHOE BOOM CYLINDER ............................................................................................................ 79

5.5 BACKHOE ATTACHMENT DIPPER CYLINDER ................................................................................ 83
5.6 BACKHOE BUCKET CYLINDER......................................................................................................... 87
5.7 TELESCOPIC CYLINDER ................................................................................................................... 91
5.8 4WS STABILIZER CYLINDER - CENTER PIVOT............................................................................... 95
5.9 STABILIZER CYLINDER - SIDESHIFT ............................................................................................... 99
5.10 SWING CYLINDER.......................................................................................................................... 103
5.11 BACKHOE ATTACHMENT SIDESHIFT CYLINDER - SIDESHIFT ................................................. 107
5.12 SPECIAL TOOLS............................................................................................................................. 108
6. HYDRAULIC CONTROL LEVERS............................................................................................................ 109
6.1 SPECIFICATIONS ............................................................................................................................. 109
6.2 DESCRIPTION AND OPERATION.................................................................................................... 110
6.4 CONTROL LEVER VALVE ................................................................................................................ 116
7. FAULT FINDING ....................................................................................................................................... 119
7.1 PRELIMINARY CHECKS................................................................................................................... 119
7.2 FAULT FINDING ................................................................................................................................ 120
SECTION 39 - CHASSIS
1. DESCRIPTION AND OPERATION............................................................................................................... 3
2. REMOVAL AND INSTALLATION COMPONENTS....................................................................................... 5
2.1 COMPONENTS WITHIN THE CHASSIS............................................................................................... 5
2.2 COMPONENTS BELOW THE CHASSIS .............................................................................................. 6
2.3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS ....................................................................... 8
2.4 COMPONENTS ATTACHED ON THE CHASSIS.................................................................................. 9
2.5 MOUNTING SCREW TORQUE........................................................................................................... 11
SECTION 41 - STEERING SYSTEM

1. STEERING SYSTEM 2WS ........................................................................................................................... 4
3. POWER STEERING ................................................................................................................................... 12
3.1 SPECIFICATIONS ............................................................................................................................... 13
3.2 COMPONENTS ................................................................................................................................... 15
3.4 SPECIAL TOOLS................................................................................................................................. 33
3.5 FAULT FINDING .................................................................................................................................. 33
SECTION 50 - CAB HEATING AND AIR CONDITIONING

1. SPECIFICATIONS ........................................................................................................................................ 3
2. CAB HEATING.............................................................................................................................................. 5
3. AIR CONDITIONING................................................................................................................................... 12
3.1 PRINCIPALS OF AIR CONDITIONING ............................................................................................... 12
3.2 SAFETY PRECAUTIONS .................................................................................................................... 16
3.3 CONTROLS AND OPERATION .......................................................................................................... 17
3.4 FAULT FINDING AND TESTING......................................................................................................... 26
3.5 FLUSHING THE SYSTEM ................................................................................................................... 44
3.6 EVACUATING THE SYSTEM.............................................................................................................. 46
3.7 CHARGING THE SYSTEM.................................................................................................................. 47
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3.8 COMPONENTS OVERHAUL .............................................................................................................. 48

3.9 COMPRESSOR ................................................................................................................................... 53
3.10 SPECIAL TOOLS............................................................................................................................... 67
SECTION 55 - ELECTRICAL SYSTEM

1. GENERALITIES............................................................................................................................................ 3
1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING.................................................................................................................................... 4
2. ELECTRICAL DIAGRAMS............................................................................................................................ 5
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (580SR).......................................................... 5
2.2 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR)........................................................... 20
2.3 ELECTRICAL DIAGRAMS - POWERSHIFT CAB (580SR)................................................................. 36
2.4 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR+/590SR) ............................................ 54
2.6 ELECTRICAL DIAGRAMS - 4WS POWERSHIFT CAB (695SR)........................................................ 84
3. CONTROLS AND INSTRUMENTS .......................................................................................................... 100
3.1 FRONT CONTROL PANELS (580SR / 590SR) ................................................................................ 100
3.2 FRONT CONTROL PANELS (695SR) .............................................................................................. 102
3.3 SIDE INSTRUMENT CLUSTER PANEL (580SR) ............................................................................. 104
3.4 SIDE INSTRUMENT CLUSTER PANEL (580SR+ / 590SR / 695SR)............................................... 106
3.5 SIDE INSTRUMENT CLUSTER (580SR).......................................................................................... 108
3.6 SIDE INSTRUMENT CLUSTER (580SR+ / 590SR / 695SR)............................................................ 110
3.7 IMMOBILISER CIRCUIT.................................................................................................................... 112
4. DIAGNOSTIC DISPLAY (580SR+ / 590SR / 695SR) ............................................................................... 113
4.1 SYMBOLS.......................................................................................................................................... 114
4.2 SETUP MENU ................................................................................................................................... 115
4.3 PROCEDURE ABOUT SELF TEST .................................................................................................. 116
4.4 ON BOARD ERROR CODE RETRIEVAL ......................................................................................... 117
4.5 BACKLIGHTING AND DIMMING....................................................................................................... 118
4.6 WORK HOURS.................................................................................................................................. 119
4.7 FUNCTIONAL DESCRIPTION .......................................................................................................... 120
4.8 WARNING SYSTEM.......................................................................................................................... 124
4.9 MAINTENANCE................................................................................................................................. 126
4.10 WARNING MESSAGES .................................................................................................................. 127
5. STARTING SYSTEM ................................................................................................................................ 134
5.2 FAULT FINDING................................................................................................................................ 135
5.3 STARTER MOTOR............................................................................................................................ 138
6. ALTERNATOR.......................................................................................................................................... 144
6.1 SPECIFICATIONS ............................................................................................................................. 144
6.3 COMPONENTS ................................................................................................................................. 146
6.4 REMOVAL ......................................................................................................................................... 147
6.5 PRELIMINARY CHECK AND TESTS................................................................................................ 148
6.6 FAULT FINDING................................................................................................................................ 157
7. BATTERY ................................................................................................................................................. 158
7.1 SPECIFICATIONS ............................................................................................................................. 158
7.3 BATTERY REPLACEMENT .............................................................................................................. 159
7.4 MAINTENANCE................................................................................................................................. 161
7.5 TESTS ............................................................................................................................................... 163
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7.6 CONNECTING A BOOSTER BATTERY ........................................................................................... 165

7.7 BATTERY MASTER SWITCH ........................................................................................................... 165
8. COMPONENT TESTING .......................................................................................................................... 166
8.1 GENERAL INTRODUCTION ............................................................................................................. 166
8.2 COMPONENT TESTING ................................................................................................................... 167
8.3 GROUND POINTS............................................................................................................................. 167
8.4 ALTERNATOR ................................................................................................................................... 170
8.5 TRANSMISSIONS ............................................................................................................................. 170
8.6 PARKING BRAKE SWITCH............................................................................................................... 174
8.7 CAB.................................................................................................................................................... 175
8.8 4WD SWITCH .................................................................................................................................... 180
8.9 BRAKE PEDAL SWITCHES .............................................................................................................. 180
8.10 BRAKE OIL LEVEL WARNING LAMP............................................................................................. 181
8.11 FRONT WORK LAMP SWITCH (1) - REAR WORK LAMP SWITCH (2) MAIN LIGHT SWITCH.... 181
8.12 HAZARD SWITCH ........................................................................................................................... 182
8.13 HAZARD WARNING LIGHT RELAY................................................................................................ 182
8.14 MULTI FUNCTION SWITCH............................................................................................................ 183
8.15 FRONT WINDSHIELD WIPER MOTOR (1) - REAR WINDSHIELD WIPER MOTOR (2) ............... 183
8.16 4WS - STEERING SELECTOR SWITCH ........................................................................................ 184
8.17 STEERING CONTROL UNIT........................................................................................................... 185
8.18 4WS REAR AXLE STEERING SENSOR......................................................................................... 187
8.19 4WS FRONT AXLE STEERING SENSOR ...................................................................................... 187
8.20 STEERING SOLENOID VALVE....................................................................................................... 188
8.21 DIFFERENTIAL LOCK SWITCH (1) ................................................................................................ 189
8.22 LOADER .......................................................................................................................................... 190
8.23 BACKHOE........................................................................................................................................ 193
SECTION 82 - LOADER
1. LOADER ATTACHMENT CONTROLS......................................................................................................... 3
1.1 LOADER ATTACHMENT OPERATION................................................................................................. 3
2. LOADER BUCKET SELF LEVELING ........................................................................................................... 6
3. LOADER ATTACHMENT SAFETY STRUT.................................................................................................. 7
4. LOADER BUCKET REMOVAL ..................................................................................................................... 8
5. LOADER REMOVAL................................................................................................................................... 11
SECTION 84 - BACKHOE
2. BACKHOE ATTACHMENT MECHANICAL CONTROLS VERSION ............................................................ 6
3. BACKHOE ATTACHMENT HYDRAULIC CONTROLS .............................................................................. 15
4. REMOVAL AND INSTALLATION ............................................................................................................... 17
4.1 CENTER PIVOT BACKHOE ATTACHMENT DISASSEMBLY ............................................................ 17
4.2 BACKHOE ATTACHMENT DISASSEMBLY - SIDESHIFT.................................................................. 20
4.3 BACKHOE BUCKET REMOVAL ......................................................................................................... 23
4.4 BUCKET TEETH REPLACEMENT...................................................................................................... 23
4.5 DIPPER REMOVE ............................................................................................................................... 24
5. TELESCOPIC DIPPER REVISION............................................................................................................. 27
7. REVISIONE DEL BRACCIO TELESCOPICO............................................................................................. 27
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580SR
580SR+
590SR
695SR
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This warning symbol points out important messages

involving personal safety.
Carefully read the safety rules contained herein and
follow advised precautions to avoid potential hazards and safeguard your safety and personal integrity.
In this manual you will find this symbol together with
the following keywords:
WARNING - it gives warning about improper repair
operations and deriving potential consequences affecting the service technicians personal safety.
DANGER - it gives specific warning about potential
dangers for personal safety of the operator or other
persons directly or indirectly involved.
TO PREVENT ACCIDENTS
Most accidents and personal injuries that occur in the work site or on the road, are caused by the failure of
some individual to follow simple and fundamental safety rules or precautions.
For this reason, MOST ACCIDENTS CAN BE PREVENTED: by recognizing the real cause and taking the necessary precautions, before the accident occurs.
Regardless of the care used in design and construction of any type of equipment, there may be conditions that
cannot be completely safeguarded against, without interfering with reasonable accessibility and efficient operation.
A careful operator or technician is the best precaution against accidents. The complete observance of one simple rule would prevent many thousands of serious injuries each year.
This rule is: never attempt to clean, lubricate or adjust a machine while it is in motion.
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SAFETY PRECAUTIONS
Z Carefully follow specified repair and maintenance
procedures.
Z Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as: ties, torn
clothes, scarves, open jackets or shirts with open
zips which could get hold into moving parts.
We advise to use approved safety clothing such
as: anti-slipping footwear, gloves, safety goggles,
helmets, etc.
Z Never carry out any repair on the machine if someone is sitting on the operators seat, except if they are
certified operators to assist in the operation to be carried out.
Z Never operate the machine or use attachments
from a place other than sitting at the operators
seat.
Z Never carry out any operation on the machine
when the engine is running, except when specifically indicated.
Z Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing
caps, covers, valves, etc.
Z All repair and maintenance operations should be
carried out with the greatest care and attention.
Z Service stairs and platforms used in a workshop or
in the field should be built in compliance with the
safety rules in force.
Z Disconnect the batteries and label all controls to
warn that the Machine is being serviced. Block the
machine and all equipment which should be
raised.
Z Never check or fill fuel tanks and accumulator batteries, nor use starting liquid if you are smoking or near
open flames as such fluids are flammable.
Z Brakes are inoperative when they are manually released for maintenance purposes. In such cases,
the machine should be kept constantly under control using blocks or similar devices.
Z The fuel filling gun should remain always in contact
with the filler neck.
Maintain this contact until the fuel stops flowing
into the tank to avoid possible sparks due to static
electricity buildup.
Z Use exclusively specified towing points for towing
the machine. Connect parts carefully. Ensure that
foreseen pins and/or locks are steadily fixed before
applying traction.
Do not stop near towing bars, cables or chains
working under load.
Z To transfer a failed machine, use a trailer or a low
loading platform trolley if available.
Z To load and unload the machine from the transportation mean, select a flat area providing a firm support to the trailer or truck wheels. Firmly tie the
machine to the truck or trailer platform and block
wheels as required by the forwarder.
Z For electrical heaters, battery-chargers and similar

equipment use exclusive auxiliary power supplies
with a efficient ground to avoid electrical shock
hazard.
Z Always use lifting equipment and similar of appropriate capacity to lift or move heavy components.
Z Pay special attention to bystanders.
Z Never pour gasoline or diesel oil into open, wide
and low containers.
Z Never use gasoline, diesel oil or other flammable
liquids as cleaning agents. Use non-flammable
non-toxic proprietary solvents.
Z Wear protection goggles with side guards when
cleaning parts using compressed air.
Z Do not exceed a pressure of 2.1 bar, in accordance
with local regulations.
Z Do not run the engine in a closed building without
proper ventilation.
Z Do not smoke, use open flames, cause sparks in
the nearby area when filling fuel or handling highly
flammable liquids.
Z Do not use flames as light sources when working
on a machine or checking for leaks.
Z Move with caution when working under a Machine,
and also on or near a Machine. Wear proper safety
accessories:
helmets, goggles and special footwear.
Z During checks which should be carried out with the
engine running, ask an assistant to sit at the operators seat and keep the service technician under
visual control at any moment. In case of operations
outside the workshop, drive the machine to a flat
area and block it. If working on an incline cannot be
avoided, first block the Machine carefully. Move it
to a flat area as soon as possible with a certain extent of safety.
Z Ruined or plied cables and chains are unreliable.
Do not use them for lifting or trailing. Always handle them wearing gloves of proper thickness.
Z Chains should always be safely fastened. Ensure
that fastening device is strong enough to hold the
load foreseen. No persons should stop near the
fastening point, trailing chains or cables.
Z The working area should be always kept CLEAN
and DRY. Immediately clean any spillage of water
or oil.
Z Do not pile up grease or oil soaked rags: they constitute a great fire hazard. Always place them into a metal container. Before starting the Machine or its
attachments, check, adjust and block the operators
seat. Also ensure that there are no persons within the
Machine or attachment operating range.
Z Do not keep in your pockets any object which might fall
unobserved into the Machines inner compartments.
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Z Whenever there is the possibility of being reached

by ejected metal parts or similar, use protection
eye mask or goggles with side guards, helmets,
special footwear and heavy gloves. Whenever it is
necessary to carry out welding operations, it is
necessary to wear suitable personal protective devices: tinted eye protection, helmets, special clothing, gloves and safety shoes. All persons standing
in the vicinity of the welding process should wear
tinted eye protection. NEVER LOOK AT THE
WELDING ARC IF YOUR EYES ARE NOT SUITABLY PROTECTED.
Z Metal cables with the use get frayed. Always wear
adequate protections (heavy gloves, eye protection, etc.).
Z Handle all parts with the greatest caution. Keep
your hands and fingers far from gaps, moving
gears and similar. Always use approved protective
equipment, such as eye protection, heavy gloves
and protective footwear.
START UP
Z Never run the engine in confined spaces which are
not equipped with adequate ventilation for exhaust
gas extraction.
Z Never bring your head, body, arms, legs, feet,
hands, fingers near fans or rotating belts.
ENGINE
Z Always loosen the radiator cap very slowly before
removing it to allow pressure in the system to dissipate. Coolant should be topped up only when the
engine is stopped or idle if hot.
Z Do not fill up fuel tank when the engine is running,
mainly if it is hot, to avoid ignition of fires in case of
fuel spilling.
Z Never check or adjust the fan belt tension when the
engine is running. Never adjust the fuel injection
pump when the machine is moving.
Z Never lubricate the machine when the engine is
running.
ELECTRICAL SYSTEMS
Z If it is necessary to use auxiliary batteries, cables
must be connected at both sides as follows: (+) to
(+) and (-) to (-). Avoid short-circuiting the terminals. GAS RELEASED FROM BATTERIES IS
HIGHLY FLAMMABLE. During charging, leave the
battery compartment uncovered to improve ventilation. Avoid checking the battery charge by
means of jumpers made by placing metallic objects across the terminals. Avoid sparks or flames
near the battery area. Do not smoke to prevent explosion hazards.
Z Prior to any service, check for fuel or coolant leaks.
Remove these leaks before going on with the work.
Do not charge batteries in confined spaces. Ensure that ventilation is appropriate to prevent accidental explosion hazard due to build-up of gasses
relieved during charging.
Z Always disconnect the batteries before performing

any type of service on the electrical system.
HYDRAULIC SYSTEMS
Z Some fluid slowly coming out from a very small
port can be almost invisible and be strong enough
to penetrate the skin. For this reason, use a piece
of cardboard or a piece of wood for checking. NEVER USE YOUR HANDS. If any fluid is injected into
the skin, seek medical aid immediately. Lack of immediate medical attention, serious infections or
dermatitis may result.
Z Always take system pressure readings using the
appropriate gauges.
WHEELS AND TYRES
Z Check that the tyres are correctly inflated at the
pressure specified by the manufacturer. Periodically check possible damages to the rims and
tyres.
Z Keep off and stay at the tyre side when correcting
the inflation pressure.
Z Check the pressure only when the machine is unloaded and tyres are cold to avoid wrong readings
due to over-pressure. Do not reuse parts of recovered wheels as improper welding, brazing or heating may weaken the wheel and make it fail.
Z Never cut, nor weld a rim with the inflated tyre assembled.
Z To remove the wheels, block both front and rear
Machine wheels. Raise the Machine and install
safe and stable supports under the Machine in accordance with regulations in force.
Z Deflate the tyre before removing any object caught
into the tyre tread.
Z Never inflate tyres using flammable gases as they
may originate explosions and cause injuries to bystanders.
REMOVAL AND INSTALLATION
Z Lift and handle all heavy components using lifting
equipment of adequate capacity. Ensure that parts
are supported by appropriate slings and hooks.
Use lifting eyes provided to this purpose. Take
care of the persons near the loads to be lifted.
Z Handle all parts with great care. Do not place your
hands or fingers between two parts. Wear approved protective clothing such as safety goggles,
gloves and footwear.
Z Do not twist chains or metal cables. Always wear
protection gloves to handle cables or chains.
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IMPORTANT ECOLOGICAL CONSIDERATIONS

The following are recommendations which may be
of assistance:
Z Become acquainted with and ensure that you understand the relative legislation applicable to your
country.
Z Where no legislation exists, obtain information
from suppliers of oils, fuels, antifreeze, cleaning
agents, etc., with regard to their effect on man and
nature and how to safely store, use and dispose of
these substances.
Helpful hints
Z Avoid filling tanks using jerry cans or inappropriate
pressurized fuel delivery systems which may
cause considerable spillage.
Z In general, avoid skin contact with all fuels, oils, acids, solvents, etc.
Most of them contain substances which can be
harmful to your health.
Z Modern oils contain additives. Do not burn contaminated fuels and/or waste oils in ordinary heating
systems.
Z Avoid spillage when draining off used engine coolant mixtures, engine, transmission and hydraulic
oils, brake fluids, etc.
Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed
of in a proper way to comply with local legislation
and available resources.
Z Modern coolant mixtures, i.e. antifreeze and other
additives, should be replaced every two years.
They should not be allowed to get into the soil but
should be collected and disposed of safely.
Z Do not open the Air-Conditioning system yourself.
It may contain gases which should not be released
into the atmosphere. Your air conditioning specialist has special equipment for discharging and
charging the system.
Z Repair any leaks or defects in the engine cooling or
hydraulic system immediately.
Z Do not increase the pressure in a pressurized system as this may lead to a catastrophic failure of the
system components.
Z Protect hoses during welding as penetrating weld
chips may burn a hole or weaken them, causing
the loss of oils, coolant, etc.
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580SR
580SR+
590SR
695SR
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All maintenance and repair operations described in

this manual should be carried out exclusively by authorized workshops. All instructions detailed should be
carefully observed and special equipment indicated
should be used if necessary. Everyone who carries out
service operations described without carefully observing these prescriptions will be directly responsible of
deriving damages.
Kinked, crushed, stretched or deformed hoses generally suffer internal structural damage which can result
in oil restriction, a reduction in the speed of operation
and ultimate hose failure.
Free-moving, unsupported hoses must never be allowed to touch each other or related working surfaces. This causes chafing which reduces hose life.
GENERAL
When repairing O-ring face seal connectors, the following procedures should be observed.
Clean the exterior of all components before carrying

out any form of repair. Dirt and dust can reduce the
efficient working life of a component and lead to
costly replacement.
Time spent on the preparation and cleanliness of
working surfaces will pay dividends in making the
job easier and safer and will result in overhauled
components being more reliable and efficient in operation. Use cleaning fluids which are known to be
safe. Certain types of fluid can cause damage to Orings and cause skin irritation. Solvents should be
checked that they are suitable for the cleaning of
components and also that they do not risk the personal safety of the user. Replace O-rings, seals or
gaskets whenever they are disturbed. Never mix
new and old seals or O-rings, regardless of condition. Always lubricate new seals and O-rings with
hydraulic oil before installation. When replacing
component parts, use the correct tool for the job.
HOSES AND TUBES
Always replace hoses and tubes if the cone end or
the end connections on the hose are damaged.
When installing a new hose, loosely connect each
end and make sure the hose takes up the designed
position before tightening the connection. Clamps
should be tightened sufficiently to hold the hose
without crushing and to prevent chafing. After hose
replacement to a moving component, check that the
hose does not foul by moving the component
through the complete range of travel. Be sure any
hose which has been installed is not kinked or twisted. Hose connections which are damaged, dented,
crushed or leaking, restrict oil flow and the productivity of the components being served. Connectors
which show signs of movement from the original
swagged position have failed and will ultimately separate completely.
A hose with a chafed outer cover will allow water entry. Concealed corrosion of the wire reinforcement
will subsequently occur along the hose length with
resultant hose failure.
Ballooning of the hose indicates an internal leakage
due to structural failure. This condition rapidly deteriorates and total hose failure soon occurs.
O-RING FLAT FACE SEAL FITTINGS
SWARNING
Never disconnect or tighten a hose or tube that is
under pressure, if in doubt, actuate the operating levers several times with the engine switched off prior
to disconnecting a hose or tube.
Release the fittings and separate the hose or tube assembly, then remove and discard the O-ring seal from
the fitting. Dip a new O-ring seal into clean hydraulic oil
prior to installation. Install a new O-ring into the fitting
and, if necessary, retain in position using petroleum jelly. Assemble the new hose or tube assembly and tighten the fitting finger tight, while holding the tube or hose
assembly to prevent it from turning. Use two suitable
wrenches and tighten the fitting to the specified torque
according to the size of the fitting.
NOTE: to ensure a leak-free joint is obtained, it is
important that the fittings are not over or under
torqued.
SHIMMING
At each adjustment, select adjusting shims, measure them individually using a micrometre and then
sum up recorded values.
Do not rely on measuring the whole shimming set,
which may be incorrect, or on rated value indicated
for each shim.
ROTATING SHAFT SEALS
To correctly install rotating shaft seals, observe the
following instructions:
Z let the seal soak into the same oil as it will seal for
at least half an hour before mounting;
Z thoroughly clean the shaft and ensure that the
shaft working surface is not damaged;
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Z place the sealing lip towards the fluid. In case of a

hydrodynamic lip, consider the shaft rotation direction and orient grooves in order that they deviate
the fluid towards the inner side of the seal;
Z coat the sealing lip with a thin layer of lubricant (oil
rather than grease) and fill with grease the gap between the sealing lip and the dust lip of double lip
seals;
Z insert the seal into its seat and press it down using
a flat punch. Do not tap the seal with a hammer or
a drift;
Z take care to insert the seal perpendicularly to its
seat while you are pressing it. Once the seal is settled, ensure that it contacts the thrust element if required;
Z to prevent damaging the sealing lip against the
shaft, place a suitable protection during installation.
O-RINGS
Lubricate the O-rings before inserting them into their
seats. This will prevent the O-rings from rolling over
and twisting during mounting which will jeopardize
sealing.
BEARINGS
It is advisable to heat the bearings to 80 to 90 C before mounting them on their shafts and cool them
down before inserting them into their seats with external tapping.
SPRING PINS
When mounting split socket spring pins, ensure that
the pin notch is oriented in the direction of the effort
to stress the pin.
Spiral spring pins should not be oriented during installation.
HARDWARE TORQUE VALUES
Check the tightness of hardware periodically. Use
the following charts to determine the correct torque
when checking, adjusting or replacing hardware on
the Backhoe loader.
IMPORTANT: Torque values listed are for general
use only. Make sure fastener threads are clean and
not damaged.
NOTE: a torque wrench is necessary to properly
torque hardware.
NOTES FOR SPARE PARTS

Only genuine parts guarantee same quality, life,
safety as original components as they are the same
as mounted in production. Only the genuine spare
parts can offer this guarantee.
All spare parts orders should be complete with the
following data:
Z machine model (commercial name) and chassis
number;
Z engine type and number;
Z part number of the ordered part, which can be
found on the Spare Parts Catalogue, which is the
base for order processing.
NOTES FOR EQUIPMENT
Equipment which proposes and shows in this manual are as follows:
Z studied and designed expressly for use on company machines;
Z necessary to make a reliable repair;
Z accurately built and strictly tested to offer efficient
and long-lasting working means.
We also remind the repair personnel that having
these equipment means:
Z work in optimal technical conditions;
Z obtain best results;
Z save time and effort;
Z work more safely.
CAUTION
Wear limits indicated for some details should be intended as advised, but not binding values. The
words front, rear, right hand, and left hand referred to the different parts should be intended as
seen from the operators seat oriented to the normal
sense of movement of the machine.
HOW TO MOVE THE MACHINE WITH THE
BATTERY REMOVED
Cables from the external power supply should be
connected exclusively to the respective terminals of
the Machine positive and negative cables using pliers in good condition which allow proper and steady
contact.
Disconnect all services (lights, wind-shield wipers,
etc.) before starting the Machine.
If it is necessary to check the machine electrical system, check it only with the power supply connected.
At check end, disconnect all services and switch the
power supply off before disconnecting the cables.
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580SR
580SR+
590SR
695SR
SECTION 02 - TECHNICAL
SPECIFICATIONS
1. LOADER BACKHOE MODELS .................................................................................................................... 3
2. IDENTIFICATION OF MAIN COMPONENTS............................................................................................... 4
3. SPECIFICATIONS ........................................................................................................................................ 6
3.1 DIESEL ENGINE ................................................................................................................................... 6
3.2 TRANSMISSION.................................................................................................................................... 8
3.3 AXLES ................................................................................................................................................... 9
3.4 BRAKES ................................................................................................................................................ 9
3.5 STEERING........................................................................................................................................... 10
3.6 HYDRAULIC SYSTEM ........................................................................................................................ 10
3.7 FRONT COUNTERWEIGHT ............................................................................................................... 10
3.8 NOISE AND VIBRATION LEVELS ...................................................................................................... 11
3.9 BUCKETS ............................................................................................................................................ 11
3.10 TYRES ............................................................................................................................................... 12
4. DIMENSIONS AND PERFORMANCE........................................................................................................ 13
4.1 LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE ....................................................... 13
4.2 DIMENSIONS AND PERFORMANCE OF LOADER ATTACHMENT WITH FORKS.......................... 19
4.3 BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE .................................................... 20
5. BACKHOE ATTACHMENT LIFTING CAPACITY ....................................................................................... 26
6. MAXIMUM LIFTING LOADS....................................................................................................................... 29
6.1 LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE ............................................................ 29
6.2 BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE ......................................................... 30
7. SUPPLY SUMMARY TABLE ...................................................................................................................... 31
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1.
LOADER BACKHOE MODELS

580SR
580SR+
590SR
695SR
Powershift
Powershuttle
Stabilizer sideshift
Stabilizer center pivot
Cab
Rops
2WD
4WD
4WS
Pilot control
Mechanical control

F4GE948C*601 (mechanical)



F4HE9484C*J103 - 4WS (electronic)
Short dipper
Long dipper
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IDENTIFICATION OF MAIN COMPONENTS
SIDESHIFT VERSION (590SR for example)
1.
2.
3.
4.
5.
6.
7.
8.
Loader bucket
Loader arm
Front axle
Fuel tank
Rear axle
Operators compartment
Engine guard
Backhoe attachment boom
9.
10.
11.
12.
13.
14.
15.
Dipper or telescopic dipper

Backhoe bucket
Backhoe attachment sideshift carriage
Stabilizers
Battery box
Hydraulic oil tank
Swing cylinders
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CENTER PIVOT VERSION (695SR for example)
1.
2.
3.
4.
5.
6.
7.
Loader bucket
Loader arm
Front axle
Fuel tank
Rear axle
Engine guard
8.
9.
10.
11.
12.
13.
14.
Backhoe attachment boom

Dipper or telescopic dipper
Backhoe bucket
Stabilizers
Battery box
Hydraulic oil tank
Swing cylinders
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3.
SPECIFICATIONS
3.1
DIESEL ENGINE
72 kW - 97 HP ENGINE (580SR)
Specifications (EEC 88/195) .................................................................................. 72 kW - 97 HP @ 2200 rpm
Model ......................................................................................................................................F4GE9484C*601
Type ......................................................................................................................................diesel, mechanical
No. of cylinders ................................................................................................................................................ 4
Valves per cylinder ........................................................................................................................................... 2
Bore....................................................................................................................................................... 104 mm
Stroke .................................................................................................................................................... 132 mm
Displacement ......................................................................................................................................4485 cm3
Compression ratio .................................................................................................................................... 17.5:1
Maximum torque (EC) .......................................................................................................400 Nm @ 1400 rpm
Low idle speed at no load ........................................................................................................... 1000 50 rpm
High idle speed at no load (engine not installed) ........................................................................ 2430 50 rpm
High idle speed at no load (engine not installed on the vehicle) ................................................. 2380 60 rpm
Maximum speed at full load ................................................................................................................ 2200 rpm
Air intake ....................................................................................................TAA (turbocharged with aftercooler)
Supply
Type ............................................................................................................................................ direct injection
Injection pump............................................................................................. BOSCH ROTARY VE 4/12 F1100L
Injection sequence ..................................................................................................................................1-3-4-2
Cold-start device .............................................................................................................grid heater (optional)
Cooling
Pump type ......................................................................................................................................... H2O pump
Pump drive ...........................................................................................................................................belt drive
Temperature switch (opening start) ..................................................................................................... 81 2 C
72 kW - 97 HP ENGINE (580SR+)
Specifications (EEC 88/195) .................................................................................. 72 kW - 97 HP @ 2200 rpm
Model .................................................................................................................................... F4HE0484G*J102
Type ........................................................................................................................................ diesel, electronic
No. of cylinders ................................................................................................................................................ 4
Bore....................................................................................................................................................... 104 mm
Stroke .................................................................................................................................................... 132 mm
Displacement ......................................................................................................................................4485 cm3
Compression ratio .................................................................................................................................... 17.5:1
Maximum torque (EC) .......................................................................................................453 Nm @ 1400 rpm
Low idle speed at no load ............................................................................................................. 950 50 rpm
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Supply
Type ........................................................................................................................high-pressure, common rail
Injection pump............................................................................................................ CP3 high-pressure pump
Control unit................................................................................................................................................EDC7
Cooling
Pump type......................................................................................................................................... H2O pump
Pump drive...........................................................................................................................................belt drive
Temperature switch (opening start)..................................................................................................... 81 2 C
82 kW - 110 HP ENGINE (590SR / 695SR)
Specifications (EEC 88/195) ................................................................................ 82 kW - 110 HP @ 2200 rpm
Model (590SR)...................................................................................................................... F4HE9484C*J102
Model (695SR)...................................................................................................................... F4HE9484C*J103
Type .........................................................................................................................................diesel, electronic
No. of cylinders ................................................................................................................................................ 4
Bore ...................................................................................................................................................... 104 mm
Stroke.................................................................................................................................................... 132 mm
Displacement ...................................................................................................................................... 4485 cm3
Compression ratio.................................................................................................................................... 17.5:1
Maximum torque (EC)....................................................................................................... 516 Nm @ 1400 rpm
Low idle speed at no load ............................................................................................................. 950 50 rpm
Supply
Type ........................................................................................................................high-pressure, common rail
Injection pump............................................................................................................ CP3 high-pressure pump
Control unit................................................................................................................................................EDC7
Cooling
Pump type......................................................................................................................................... H2O pump
Pump drive...........................................................................................................................................belt drive
Temperature switch (opening start)..................................................................................................... 81 2 C
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3.2
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TRANSMISSION
2WD/2WS TRANSMISSION - POWERSHUTTLE (580SR)

Model ...............................................................................................................................Turner COM-T4-2025
Type (4x4) ................................................................................................ 4 forward and 4 reverse travel gears
Torque converter ratio ................................................................................................................................. 2.38
Transmission ratios:
1st forward travel.....................................................................gear 4.824:1
reverse travel gear 4.020:1
2nd forward travel ...................................................................gear 2.998:1
3rd forward travel ....................................................................gear 1.408:1
4th forward travel ....................................................................gear 0.792:1
4WD/2WS TRANSMISSION - POWERSHUTTLE (580SR+ / 590SR)
Model ...............................................................................................................................Turner COM-T4-2025
Torque converter ratio ................................................................................................................................. 2.38
4WD/2WS TRANSMISSION - POWERSHIFT (580SR+ / 590SR)
Model ........................................................................................................................................... Dana T16000
Torque converter ratio ............................................................................................................................... 2.261
(upper output)
(lower output)
4WD/4WS TRANSMISSION - POWERSHIFT (695SR)
Model ........................................................................................................................................... Dana T16000
Torque converter ratio ............................................................................................................................... 2.261
(upper output)
(lower output)
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3.3
AXLES
FRONT AXLES
Front 2WD/2WS axle (580SR)
Model ..................................................................................................................................... CARRARO 26.00
Type .......................................................................................................................................................steering
Front 4WD/2WS axle (580SR / 590SR)
Model ..................................................................................................................................... CARRARO 26.16
Type .......................................................................................................................................................steering
Front 4WD/4WS axle (695SR)
Model ..................................................................................................................................... CARRARO 26.28
Type .......................................................................................................................................................steering
REAR AXLES
Rear 2WS axle (580SR / 590SR)
Model .................................................................................................................................................. CNH D46
Type .............................................................................................................................................................rigid
Differential lock (powershuttle axle) ................................................................................................. mechanical
Differential lock (powershift axle) ......................................................................................................... electrical
Rear 4WS axle (695SR)
Model .................................................................................................................................. CARRARO 26.32M
Type .......................................................................................................................................................steering
Differential lock .................................................................................................................................... electrical
3.4
BRAKES
BRAKES - 2WS
Service brake
Type .......................................................................................................wet multi-discs, 8 x axle (4 x half axle)
Braking surface ................................................................................................................................... 1440 cm2
Parking brake
Type ........................................................................................................................ single disc on transmission
BRAKES - 4WS
Service brake
Type .......................................................................................................wet multi-discs, 6 x axle (3 x half axle)
Braking surface ................................................................................................................................... 1440 cm2
Parking brake
Type ........................................................................................................................ single disc on transmission
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3.5
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STEERING
2WS ..............................................................................................................................................2 wheel steer

4WS ..............................................................................................................................................4 wheel steer
System pressure .............................................................................................................................. 177 3 bar
POWER STEERING
2WS
Model ........................................................................................................................ DANFOSS OSPC 125 LS
Displacement ..................................................................................................................................125 cm3/rev
Shock valve adjustment ......................................................................................................................... 225 bar
Pressure relief valve adjustment ............................................................................................................ 170 bar
4WS
Model ........................................................................................................................ DANFOSS OSPC 160 LS
Displacement ..................................................................................................................................160 cm3/rev
Shock valve adjustment ......................................................................................................................... 225 bar
Pressure relief valve adjustment ............................................................................................................ 170 bar
3.6
HYDRAULIC SYSTEM
HYDRAULIC PUMP
Pump 72 kW - 97 HP (580SR)
Model ..........................................................................................................CASAPPA KP 30.34 - 05 S6 - LMF
Type ............................................................ double gear pump: hydraulic system and priority steering system
Displacement ..............................................................................................................35.427 + 35.427 cm3/rev
Pump 82 kW - 110 HP (590SR / 695SR)
Model ..........................................................................................................CASAPPA KP 30.38 - 05 S6 - LMF
Type ............................................................ double gear pump: hydraulic system and priority steering system
Displacement ..............................................................................................................40.258 + 35.427 cm3/rev
3.7
FRONT COUNTERWEIGHT
Weight ..................................................................................................................................................... 160 kg
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3.8
11
NOISE AND VIBRATION LEVELS
NOISE LEVEL
Certified by the Manufacturer.
In compliance with European Directive 2000/14/EC - Stage II.
Internal noise level (LpA) .......................................................................................................................... 77 db
External noise level (LwA) (580SR) ........................................................................................................ 102 db
External noise level (LwA) (590SR / 695SR) .......................................................................................... 103 db
VIBRATION LEVEL INSIDE THE CAB
Upper limbs................................................................................................................. level lower than 2.5 m/s2
Abdomen..................................................................................................................... level lower than 0.5 m/s2
3.9
BUCKETS
LOADER BUCKETS
2WS
Type
0.88 m3
standard
1 m3 standard
4x1
6x1 (with forks)
Heaped capacity
0.88 m3
1.0 m3
1.0 m3
1.0 m3
Width
2,250 mm
2,250 mm
2,250 mm
2,250 mm
Weight
310 kg
410 kg
800 kg
960 kg
Heaped capacity
1.15 m3
1.15 m3
1.15 m3
Width
2,400 mm
2,400 mm
2,400 mm
Weight
426 kg
830 kg
990 kg
4WS
BACKHOE BUCKETS
Struck capacity SAE J 296
Width
Weight
76 l
305 mm
108 kg
109 l
457 mm
130 kg
153 l
610 mm
160 kg
196 l
762 mm
180 kg
238 l
914 mm
208 kg
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3.10 TYRES
TYRE TYPES
Tyres - 2WS
2WD
4WD
Front tyres
Rear tyres
11L-16 F3 12PR
18.4-26 R4 12PR
11L-16 F3 12PR
16.9-28 R4 12PR
12.5/80 - 18 L3 10PR
18.4-26 R4 10PR
12.5/80 - 18 L3 10PR
16.9-28 R4 10PR
320/80 R18 IT 520
480/80 R26 IT520
Tyres - 4WS
Front and rear tyres
16.9/24 R4 12PR
16.9/28 R4 12PR
440/80 R28 IT520
440/80 R28 IT530
NUT TORQUES
Front nuts (2WS)....................................................................................................................................330 Nm
Rear nuts (2WS) ....................................................................................................................................540 Nm
Front and rear nuts (4WS) .....................................................................................................................700 Nm
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4.
DIMENSIONS AND PERFORMANCE
4.1
LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE
580SR / 580SR+ / 590SR
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
P.
Maximum height
Maximum height of loader bucket pin/pivot
Maximum dumping height
Angle of lowered closed bucket
Angle of closed bucket at maximum height
Loader attachment reach when raised in dumping position
Cab height
Digging depth
Loader bucket reach
Wheel base
Rear wheel base - backhoe attachment swing
support
Backhoe bucket dimensions
Overall machine length
Maximum machine height
Stabilizer width
Loader bucket width
13
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14
TYRES
FRONT
REAR
2WD
11L-16F
18.4-26
4WD
12.5/80-18
18.4-26
Dimensions
2WD with standard bucket
4WD with standard bucket
4130 mm
4250 mm
3345 mm
3460 mm
2550 mm
2685 mm
45
45
45
45
875 mm
830 mm
2950 mm
2950 mm
240 mm
120 mm
2060 mm
1973 mm
2175 mm
2175 mm
1325 mm
1325 mm
1630 mm
1630 mm
5865 mm
5778 mm
4000 mm
4000 mm
2430 mm
2430 mm
2250 mm
2250 mm
Performance
2WD
4WD
Lifting capacity at
maximum height
3325 kg
3450 kg
Breakout force
6556 daN
6537 daN
LOADER BUCKETS
Type
Normal operation
4x1
6x1 (with forks)
Heaped capacity
1.00 m3
1.00 m3
1.00 m3
Width
2250 mm
2250 mm
2250 mm
Weight
410 kg
800 kg
960 kg
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695SR (SIDESHIFT)
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
P.
Maximum height
Cab height
Digging depth
Loader bucket reach
Wheel base
support
Stabilizer width
Loader bucket width
15
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16
TYRES
FRONT
REAR
440/80R28
440/80R28
Dimensions
Standard bucket
Bucket 4x1
6x1 bucket (with

forks)
4347 mm
4460 mm
4460 mm
3491 mm
3518 mm
3518 mm
2717 mm
2753 mm
2753 mm
45
45
45
45
45
45
744 mm
690mm
690mm
2900 mm
2900 mm
2900 mm
113 mm
90 mm
90 mm
1975 mm
1980 mm
1980 mm
2200 mm
2200 mm
2200 mm
1324 mm
1324 mm
1324 mm
1630 mm
1630 mm
1630 mm
5783 mm
5788 mm
5788 mm
3935 mm
3935 mm
3935 mm
2480 mm
2480 mm
2480 mm
2400 mm
2400 mm
2400 mm
Performance
Standard bucket
Bucket 4x1
6x1 bucket (with

forks)
Lifting capacity at
maximum height
3386 kg
3075 kg
2950 kg
Breakout force
5413 daN
5600 daN
5600 daN
LOADER BUCKETS
Type
Normal operation
4x1
6x1 (with forks)
Heaped capacity
1.15 m3
1.15 m3
1.15 m3
Width
2400 mm
2400 mm
2400 mm
Weight
426 kg
830 kg
990 kg
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695SR (CENTER PIVOT)
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
P.
Maximum height
Cab height
Digging depth
Loader bucket reach
Wheel base
support
Stabilizer width
Loader bucket width
17
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18
TYRES
FRONT
REAR
16.9-28
16.9-28
Dimensions
Standard bucket
Bucket 4x1
6x1 bucket (with

forks)
4347 mm
4460 mm
4460 mm
3491 mm
3518 mm
3518 mm
2717 mm
2753 mm
2753 mm
45
45
45
45
45
45
744 mm
690 mm
690 mm
2900 mm
2900 mm
2900 mm
113 mm
90 mm
90 mm
1975 mm
1980 mm
1980 mm
2200 mm
2200 mm
2200 mm
1324 mm
1324 mm
1324 mm
3040 mm
3040 mm
3040 mm
7220 mm
7225 mm
7225 mm
3935 mm
3935 mm
3935 mm
2230 mm
2230 mm
2230 mm
2400 mm
2400 mm
2400 mm
Performance
Standard bucket
Bucket 4x1
6x1 bucket (with

forks)
Lifting capacity at
maximum height
3386 kg
3075 kg
2950 kg
Breakout force
5413 daN
5600 daN
5600 daN
LOADER BUCKETS
Type
Normal operation
4x1
6x1 (with forks)
Heaped capacity
1.15 m3
1.15 m3
1.15 m3
Width
2400 mm
2400 mm
2400 mm
Weight
426 kg
830 kg
990 kg
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4.2
19
DIMENSIONS AND PERFORMANCE OF LOADER ATTACHMENT WITH FORKS
Fork spacing - Minimum centres ........................................................................................................... 275 mm

Fork spacing - Maximum centres ........................................................................................................ 1773 mm
Fork length .......................................................................................................................................... 1026 mm
Fork width ............................................................................................................................................... 80 mm
580SR / 580SR+ / 590SR
A.
B.
C.
D.
Reach full height ........................................................................................................................... 2319 mm

Reach ground level ....................................................................................................................... 3186 mm
Lift height ...................................................................................................................................... 2998 mm
Lift height ...................................................................................................................................... 3458 mm
695SR
A.
B.
C.
D.
Reach full height ........................................................................................................................... 2194 mm

Reach ground level ....................................................................................................................... 3186 mm
Lift height ...................................................................................................................................... 3059 mm
Lift height ...................................................................................................................................... 3518 mm
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4.3
Copyright
BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE
580SR / 580SR+ / 590SR
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
Maximum reach when loaded

Bucket rotation
Operating height, fully raised
Maximum height at full load
Reach from swing post
Reach from rear axle centre line
Maximum length of surface excavation
Maximum digging depth
Stabilizer spread - transport
Stabilizer spread - working
Stabilizer pad levelling angle
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TYRES
21
FRONT
REAR
12.5/80-18
18.4-26
Dimensions
standard dipper
telescopic dipper (extended)
1828 mm
2757 mm
200
204
5837 mm
6537 mm
3917 mm
4645 mm
5906 mm
6992 mm
7231 mm
8317 mm
6454 mm
7540 mm
4612 mm
5799 mm
2280 mm
2280 mm
2790 mm
2790 mm
14
14
Performance
standard dipper
Swing arc
180
180
Maximum digging force - dipper

cylinder
3623 daN
2581 daN
Maximum digging force - bucket

cylinder
5234 daN
5234 daN
Lift capacity through dipper arc
1975 kg
1470 kg
Lift capacity, dipper 3.66 m above

ground
2040 kg
1490 kg
Lift capacity at 4.26 m above

ground
1590 kg
1040 kg
Telescopic dipper extension

length
1200 mm
BACKHOE BUCKETS
Width
Weight
76 l
305 mm
108 kg
109 l
457 mm
130 kg
153 l
610 mm
160 kg
196 l
762 mm
180 kg
238 l
914 mm
208 kg
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22
Copyright
695SR (SIDESHIFT)
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.

Bucket rotation
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TYRES
23
FRONT
REAR
440/80R28
440/80R28
Dimensions
standard dipper
1899 mm
2844 mm
200
200
5815 mm
6492 mm
3908 mm
4615 mm
5903 mm
6990 mm
7228 mm
8315 mm
6518 mm
7605 mm
4623 mm
5805 mm
2280 mm
2280 mm
2790 mm
2790 mm
14
14
Performance
standard dipper
Swing arc
180
180

cylinder
3623 daN
2591 daN

cylinder
5234 daN
5234 daN
2260 kg
1610 kg

ground
2325 kg
1610 kg

ground
1520 kg
1000 kg

length
1200 mm
BACKHOE BUCKETS
Width
Weight
76 l
305 mm
108 kg
109 l
457 mm
130 kg
153 l
610 mm
160 kg
196 l
762 mm
180 kg
238 l
914 mm
208 kg
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24
Copyright
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.

Bucket rotation
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TYRES
25
FRONT
REAR
440/80R28
440/80R28
Dimensions
standard dipper
1870 mm
2855 mm
200
200
5737 mm
6421 mm
4002 mm
4686 mm
5836 mm
6922 mm
7161 mm
8247 mm
6346 mm
7432 mm
4556 mm
5738 mm
2280 mm
2280 mm
2790 mm
2790 mm
14
14
Performance
standard dipper
Swing arc
180
180

cylinder
3744 daN
2643 daN

cylinder
5603 daN
5603 daN
2350 kg
1560 kg

ground
2475 kg
1560 kg

ground
1470 kg
950 kg

length
1200 mm
BACKHOE BUCKETS
Width
Weight
76 l
305 mm
108 kg
109 l
457 mm
130 kg
153 l
610 mm
160 kg
196 l
762 mm
180 kg
238 l
914 mm
208 kg
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26
5.
BACKHOE ATTACHMENT LIFTING CAPACITY
580SR / 580SR+ / 590SR

Lifting capacity in normal operating mode - SAE
rated
The following table reports the lifting capacities of the
dipper (A) and the boom (B).
NOTE: the capacities indicated may slightly vary
from one machine to another, according to the accessories mounted, the pressure settings and the
market requirements.
Lifting capacities are given in kg for a standard dipper and a telescopic dipper.
Standard dipper
Dipper - A
Boom - B
Telescopic dipper
(retracted)
Dipper - A
Boom - B
Telescopic dipper
(extended)
Dipper - A
Height/Depth
Boom - B
610
+5.4
920
+4.9
1200
1120
1590
1490
1515
1040
+4.3
2040
1690
1930
1580
1490
1100
+3.6
1975
1710
1870
1590
1470
1125
+3.0
2010
1650
1900
1540
1490
1135
+2.4
2165
1560
2050
1440
1555
1135
+1.8
2630
1510
2495
1390
1685
1105
+1.2
3860
1490
3690
1370
1950
1090
+0.6
1500
1375
2785
1090
0 (ground)
1540
1405
3850
1100
-0.6
1530
1380
1110
-1.2
1520
1370
1115
-1.8
1540
1380
1125
-2.4
1605
1435
1155
-3.0
1875
1675
1210
-3.6
1360
-4.2
1930
-4.8
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27
695SR (SIDESHIFT)
rated
Standard dipper
Dipper - A
Boom - B
Telescopic dipper
(retracted)
Dipper - A
Boom - B
Telescopic dipper
(extended)
Dipper - A
Height/Depth
Boom - B
570
+5.4
865
+4.9
1120
1040
1520
1415
1510
1000
+4.3
2325
1650
2215
1535
1610
1070
+3.6
2260
1680
2150
1560
1645
1105
+3.0
2300
1675
2190
1550
1670
1120
+2.4
2480
1660
2360
1530
1760
1125
+1.8
3015
1630
2885
1500
1885
1130
+1.2
4400
1605
4230
1470
2135
1125
+0.6
1580
1440
3250
1125
0 (ground)
1560
1415
4420
1120
-0.6
1550
1400
1125
-1.2
1550
1400
1130
-1.8
1575
1415
1145
-2.4
1660
1490
1180
-3.0
2025
1815
1245
-3.6
1420
-4.2
2155
-4.8
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28

rated
Standard dipper
Dipper - A
Boom - B
Telescopic dipper
(retracted)
Dipper - A
Boom - B
Telescopic dipper
(extended)
Dipper - A
Height/Depth
Boom - B
605
+5.4
905
+4.9
1075
990
1470
1365
1460
950
+4.3
2270
1600
2165
1485
1560
1020
+3.6
2195
1630
2090
1510
1595
1055
+3.0
2240
1625
2135
1500
1620
1070
+2.4
2445
1610
2330
1480
1700
1075
+1.8
3090
1580
2960
1450
1835
1080
+1.2
4960
1555
4790
1420
2080
1075
+0.6
1530
1390
3425
1075
0 (ground)
1510
1365
5065
1070
-0.6
1500
1350
1075
-1.2
1500
1345
1080
-1.8
1525
1365
1090
-2.4
1610
1440
1130
-3.0
1970
1760
1195
-3.6
1370
-4.2
2105
-4.8
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6.
MAXIMUM LIFTING LOADS
6.1
LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE
2WS
4WS
29
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30
6.2
2WS
4WS
Copyright
BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE
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7.
31
SUPPLY SUMMARY TABLE
RECOMMENDED FLUIDS AND

APPLICATION
ENGINE - OIL
Akcela No 1 Engine oil (15W40)
CASE
Specifications
INTERNATIONAL
Specifications
MA 1121
API CH-4, ACEA E5
MA 1710
HYDRAULIC SYSTEM
Akcela Nexplore
MODELS
QUANTITY
Litres
2WS - with filter

4WS - with filter
14
12.8
CUNA NC 956-16
ALL
24
MA 3525
API GL4 ISO VG 32/46
2WS
4WS
140
118
Akcela Hydraulic Excavator Fluid Bio
MS 1230
ISO VG 46
DIN 51524 - part II
2WS
4WS
140
118
POWERSHUTTLE TRANSMISSION
Akcela Nexplore
MAT 3525
ALL
18
ATF DEXRON III
ALL
14
Differential
6.5
Wheel reduction gear

(each)
0.7
Differential
10.5

(each)
1.3
COOLING SYSTEM
Akcela Premium Anti-freeze
antifreeze 50% water 50%
POWERSHIFT TRANSMISSION
Akcela Trans XHD
FRONT AXLE (2WS)
Akcela Hy-Tran Ultra
MAT 3525
FRONT AXLE (4WS)

Akcela Nexplore
MAT 3525
REAR AXLE (2WS)

Akcela Hy-Tran Ultra
+
AOA axle oil additive
MAT 3525
REAR AXLE (4WS)

Akcela Nexplore
MAT 3525
21.2
0.8
BRAKE SYSTEM
Akcela LHM Fluid
Mineral oil
ISO 7308
FUEL
Decanted and filtered diesel fuel
Differential
11

(each)
1.3
ALL
2WS
4WS
145
124
VARIOUS JOINTS
Akcela Multi-purpose grease
251H EP
NLGI 2
ALL
As required
TELESCOPIC DIPPER
Akcela Moly Grease
251 H EP-M
NLGI 2
ALL
As required
ALL
240 cc
AIR CONDITIONING COMPRESSOR

PAG SP 20 oil
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32
NOTES:
Copyright
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580SR
580SR+
590SR
695SR

1. POWERSHUTTLE TORQUE CONVERTER ................................................................................................ 3
1.2 SPECIFICATIONS ................................................................................................................................. 4
1.3 OVERHAUL ........................................................................................................................................... 4
1.4 INSPECTION ......................................................................................................................................... 4
1.6 STALL TEST.......................................................................................................................................... 5
1.7 FAULT FINDING.................................................................................................................................... 6
2. POWERSHIFT TORQUE CONVERTER ...................................................................................................... 7
2.2 SPECIFICATIONS ................................................................................................................................. 8
2.3 OVERHAUL ........................................................................................................................................... 8
2.4 INSPECTION ......................................................................................................................................... 9
2.6 STALL TEST........................................................................................................................................ 11
2.7 FAULT FINDING.................................................................................................................................. 12
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1.
POWERSHUTTLE TORQUE CONVERTER
1.1
DESCRIPTION AND OPERATION
The torque converter is the connection between the

engine and the transmission and is hydraulically actuated. The main parts of the torque converter (A)
are the impeller (pump), the turbine, the stator and
the front and rear covers. The impeller is integral
with the rear cover and is driven by the engine flywheel by means of a drive plate. The stator, is
splined to a stationary shaft (stator support) through
a one-way clutch that permits the stator to rotate
only in the same direction as the impeller. All of the
converter parts are enclosed in an oil-filled housing.
The front and rear cover, being welded together,
form the housing. The turbine (2), splined to the front
input shaft, is splined to a stationary shaft (stator
support) through a one-way clutch that permits the
stator (3) to rotate only in the same direction as the
impeller (1). All of the converter parts are enclosed
in an oil-filled housing. When the engine is running,
the oil in the converter flows from the impeller (1) to
the turbine (2) and back to the impeller through the
stator (3). This flow produces a maximum torque increase. When enough oil flow is developed by the
impeller, the turbine begins to rotate, driving the
front input shaft. The torque multiplication gradually
decreases as turbine speed approaches impeller
speed, and becomes 1 to 1 when the turbine is being
driven at nine tenths impeller speed.
When the turbine (2) is rotating at approximately nine

tenths impeller speed, the converter stops multiplying
torque because the oil is now acting on the rear face
of the stator blades (4). The action of the oil on the
rear face of the stator unlocks the one-way clutch (5),
permitting the stator to rotate in the same direction as
the turbine (2) and impeller (1). Through this action
the converter becomes an efficient fluid coupling by
transmitting engine torque from the impeller to the turbine. To achieve optimum operation the engine performance, transmission ratios, hydraulic power
delivery and converter torque multiplication are all
Matched to provide the necessary vehicle drive
torque when required. When the turbine is rotating
less than nine tenths impeller speed (1), the converter
is multiplying torque through the action of the stator
(3). This action, produced by oil acting on the front
face of the stator blades, tends to rotate the stator in
the opposite direction of the impeller (1) and turbine
(2). However, the one-way clutch prevents this opposite rotation and allows the stator to direct oil back to
the impeller, thereby producing torque multiplication.
Maximum torque multiplication is achieved when the
impeller is driven at stall speed and the turbine is stationary.
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1.2
Copyright
SPECIFICATIONS
Torque converter ratio............................................................................................................................... 2.38:1

Weight ..................................................................................................................................................... 17.4 kg
Torque of retaining screws for transmission .............................................................................................58 Nm
Torque of retaining screw for flywheel ......................................................................................................41 Nm
Torque of screw for drive plate to the convertor........................................................................................53 Nm
Torque of screw for drive plate to the flywheel..........................................................................................41 Nm
Hydraulic tests
Tachometer setting .............................................................................................................................. 2000 rpm
Test temperature, oil ............................................................................................................................. 80-85 C
Cold start valve (for reference only) .......................................................................................................... 26 bar
System pressure test .....................................................................................................................13.7-15.2 bar
Torque converter....................................................................................................................................7-11 bar
1.3
OVERHAUL
The torque converter, is a welded unit and cannot be

disassembled. The only maintenance performed on
the converter, other than the stall test, is cleaning
and visual inspection. A commercial torque converter cleaner may be used to clean the converter. However, if a commercial cleaner is not available, the
converter should be cleaned as outlined below.
Z Drain as much oil as possible from the hub of the
converter by tilting the converter in all directions.
Z Fill the converter about half full, through the hub
(1), with paraffin base solvent or any cleaning solvent specified for cleaning transmissions.
Z Plug the opening in the hub, then circulate the solvent inside the converter by rotating and shaking.
Z Drain the solvent from the converter.
Z Repeat previous steps, as required, until the solvent that is drained from the converter is clean.
1.4
INSPECTION
Inspect the splines on the converter hub for wear or

damage and the weld joints for cracks. If the hub is
worn or damaged and/or the weld joints cracked, a
new converter must be installed. A new drive plate
should also be installed if it is warped.
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1.5
DISASSEMBLY AND ASSEMBLY
Z Secure the drive plate (3) to the torque converter (5),

with the attaching bolts and flat washers (1).
Z Tighten bolts to 53 Nm.
Z Prior to fitting the transmission place the torque
converter carefully over the transmission shaft and
into the transmission housing.
Z With the transmission bolted to the engine secure
the drive plate to the flywheel (6) accessed through
the starter motor aperture, with the attaching bolts
and washers (2). Tighten bolts to 41 Nm.
1.6
STALL TEST
The purpose of this test is to determine if the torque

converter and hydraulic clutch assemblies are operating satisfactorily.
For the test to be conclusive, the transmission hydraulic pump and pressure regulating valve must be
operating correctly.
They can be checked by performing the Line Pressure Test.
The engine and brakes must also be in good working
order.
Z Check the coolant level in the radiator and the oil level
in the transmission. If low, add fluid as required to
bring to the proper level.
Z With the gearshift lever and the shuttle lever in neutral, start the engine and run at 800-1000 rpm until
the transmission temperature reaches 29 C - 35
C.
Z Lock the brakes and shift into fourth gear, increase
engine speed to approximately 900 rpm, then shift
the power reversing lever to the forward position.
This will position the control valve so as to direct
high pressure oil to the front clutch.
Z Ensure the brakes are firmly locked so the unit will
not move, gradually depress the foot accelerator
and note the maximum engine speed obtained.
Move the power reversing lever to the neutral position. The stall speed should be:
Engine 97 HP............................... 1750 1850 rpm
Engine 110 HP............................. 1990 2140 rpm
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IMPORTANT: to prevent the transmission from

overheating, do not allow the engine to operate at
wide open throttle for more than fifteen seconds.
Z Allow the transmission oil to cool to 29 C - 35 C.
Check the rear hydraulic clutch by repeating previous
steps, but with the power reversing lever in the rearward position. Again, cool the transmission oil by allowing the engine to run at approximately 1000 rpm
for one minute.
Z The engine speed noted previously (stall speed) for
both the front and rear clutch assemblies should be
within 150 rpm of each other. If the stall speed is not
within these limits, refer to the diagnosis guide for
possible causes.
Z With the gearshift lever and power reversing lever
in neutral, set the engine speed at 600-800 rpm,
then shift into any gear ratio. If the gears clash, either the front or rear hydraulic clutch assembly is
transmitting power, even though the power reversing lever is in neutral.
NOTE: if the unit creeps forward and the gears
clash, the front clutch is at fault. The rear clutch is at
fault if the unit creeps backward. If the unit does not
creep and the gears still clash, use the stabilizers to
raise the rear wheels off the ground, move the power
reversing lever to neutral and shift into first gear.
Check the rear wheels for rotational direction; if the
wheel rotate rearward, then the rear clutch is at fault.
1.7
FAULT FINDING
PROBLEM
CAUSE
CORRECTION
Low stall speed
Hydraulic clutch not releasing

Stator support broken
Defective torque converter
Low engine power
Replace the torque converter.

Check and correct output.
High stall speed
Hydraulic clutch not applying or is

slipping
Low line pressure
Sealing rings on rear input shaft
broken
Replace.
Check pump output.
Replace the seals.
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2.
POWERSHIFT TORQUE CONVERTER
2.1
Engine power is transmitted from the engine flywheel to the impeller through the impeller cover.
This element is the pump portion of the torque converter and is the primary component which starts the oil flowing
to the other components which results in torque multiplication. This element can be compared to a centrifugal pump
in that it picks up fluid at its centre discharges at its outer diameter. The torque converter turbine is mounted opposite
the impeller and is connected to the turbine shaft or clutch shaft. This element receives fluid at its outer diameter and
discharges at its centre. The stator of the torque converter is located between and at the centre of the inner diameters of the impeller and turbine elements. Its function is to take the fluid which is exhausting from the inner portion of
the turbine and change its direction to allow correct entry for recirculation into the impeller element. This recirculation
causes the converter to multiply torque. The torque multiplication depends on the regularity of certain elements (fan,
turbine and stator) and on the output speed of the converter (turbine speed). The converter will multiply engine
torque to its designed maximum multiplication ratio when the turbine shaft is at zero RPM (stall). Therefore we can
say that as the turbine shaft is decreasing in speed, the torque multiplication is increasing. In the impeller cover a
splined shaft is fitted which runs inside and through the turbine shaft to drive a hydraulic pump which is fitted at the
back of the transmission. Since the shaft is connected to the centre of the impeller cover, the pump speed will be
the same as engine speed. The rear side of the impeller cover has a tanged drive which drives the transmission
charging pump located in the converter housing. The transmission charging pump speed is also the same as the
engine speed.
TORQUE CONVERTER AND LUBRICATION PRESSURE TEST PORTS
1. System pressure port

2. Torque converter in port
3. Torque converter out port
4. Oil temperature converter out port

5. Oil temperature cooler out port
6. Lubrication pressure port
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2.2
Copyright
SPECIFICATIONS
Torque converter ratio............................................................................................................................... 2.38:1

Torque of retaining screws for transmission .............................................................................................26 Nm
Torque of retaining screw for flywheel ......................................................................................................43 Nm
Torque of screw for drive plate..................................................................................................................43 Nm
Hydraulic tests
Torque converter relief valve..................................................................................................................... 10 bar
Oil temperature converter out:
Normal operating range .............................................................................................................. 80-90 C
Maximum temperature ................................................................................................................... 120 C
2.3
OVERHAUL
The torque converter, is a welded unit and cannot be

disassembled. The only maintenance performed on
the converter, other than the stall test, is cleaning
and visual inspection. A commercial torque converter cleaner may be used to clean the converter. However, if a commercial cleaner is not available, the
converter should be cleaned as outlined below.
Z Drain as much oil as possible from the hub of the
converter by tilting the converter in all directions.
Z Fill the converter about half full, through the hub
(1), with paraffin base solvent or any cleaning solvent specified for cleaning transmissions.
Z Plug the opening in the hub, then circulate the solvent inside the converter by rotating and shaking.
Z Drain the solvent from the converter.
Z Repeat previous steps, as required, until the solvent that is drained from the converter is clean.
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2.4
INSPECTION
Inspect the splines on the converter hub for wear or

damage and the weld joints for cracks. If the hub is
worn or damaged and/or the weld joints cracked, a
new converter must be installed. A new drive plate
should also be installed if it is warped.
2.5
DISASSEMBLY
Remove the drive plate screws.
Remove the drive plates.
Remove the torque converter assy.
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Copyright
ASSEMBLY
Install the converter assembly on the input shaft.
Install the drive plates on the converter.
Install the drive plates screws and the lock washers

and tighten the screws to the specified torque
43 Nm.
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2.6
11
STALL TEST
The purpose of this test is to determine if the torque

converter and hydraulic clutch assemblies are operating satisfactorily.
For the test to be conclusive, the transmission hydraulic pump and pressure regulating valve must be
operating correctly.
They can be checked by performing the Line Pressure Test.
The engine and brakes must also be in good working order.
Z Check the coolant level in the radiator and the oil
level in the transmission. If low, add fluid as required to bring to the proper level.
Z With the gearshift lever and the shuttle lever in neutral, start the engine and run at 800-1000 rpm until
the transmission temperature reaches 29 C - 35 C.
Z Lock the brakes and shift into fourth gear, increase
engine speed to approximately 900 rpm, then shift
the power reversing lever to the forward position.
This will position the control valve so as to direct
high pressure oil to the front clutch.
Z Ensure the brakes are firmly locked so the unit will
not move, gradually depress the foot accelerator
and note the maximum engine speed obtained.
Move the power reversing lever to the neutral position. The stall speed should be:
Engine 97 HP............................... 1750 1850 rpm
Engine 110 HP............................. 1990 2140 rpm
IMPORTANT: to prevent the transmission from
overheating, do not allow the engine to operate at
wide open throttle for more than fifteen seconds.
Z Allow the transmission oil to cool to 29 C - 35 C.
Check the rear hydraulic clutch by repeating previous steps, but with the power reversing lever in the
rearward position. Again, cool the transmission oil
by allowing the engine to run at approximately 1000
rpm for one minute.
Z The engine speed noted previously (stall speed)
for both the front and rear clutch assemblies
should be within 150 rpm of each other. If the stall
speed is not within these limits, refer to the diagnosis guide for possible causes.
Z With the gearshift lever and power reversing lever
in neutral, set the engine speed at 600-800 rpm,
then shift into any gear ratio. If the gears clash, either the front or rear hydraulic clutch assembly is
transmitting power, even though the power reversing lever is in neutral.
NOTE: if the unit creeps forward and the gears

clash, the front clutch is at fault. The rear clutch is at
fault if the unit creeps backward. If the unit does not
creep and the gears still clash, use the stabilizers to
raise the rear wheels off the ground, move the power reversing lever to neutral and shift into first gear.
Check the rear wheels for rotational direction; if the
wheel rotate rearward, then the rear clutch is at
fault.
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2.7

FAULT FINDING
PROBLEM
CAUSE
CORRECTION
Low stall speed
Hydraulic clutch not releasing

Stator support broken
Low engine power

Check and correct output.
High stall speed
Hydraulic clutch not applying or is

slipping
Low line pressure
Sealing rings on rear input shaft
broken
Replace.
Check pump output.
Replace the seals.
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580SR
580SR+
590SR
695SR
1. POWERSHUTTLE TRANSMISSION TURNER MODEL COM-T4-2025 ................................................... 3
1.1 SPECIFICATIONS ................................................................................................................................. 3
1.2 MOUNTING SCREW TORQUE............................................................................................................. 5
1.3 TRANSMISSION CONTROLS............................................................................................................... 6
1.4 LUBRICATION..................................................................................................................................... 11
1.5 TRANSMISSION OIL FLOW AND SUPPLY........................................................................................ 12
1.6 TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS....................................... 18
1.7 TRANSMISSION POWER FLOW........................................................................................................ 19
1.8 TRANSMISSION 2WD COMPONENTS.............................................................................................. 23
1.9 TRANSMISSION 4WD COMPONENTS.............................................................................................. 26
1.10 TRANSMISSION REMOVAL ............................................................................................................. 31
1.12 FAULT FINDING................................................................................................................................ 90
1.13 SPECIAL TOOLS............................................................................................................................... 93
2. POWERSHIFT TRANSMISSION DANA T16000 ..................................................................................... 94
2.1 SPECIFICATIONS ............................................................................................................................... 94
2.2 CONTROLS ......................................................................................................................................... 95
2.3 LUBRICATION................................................................................................................................... 105
2.4 PRESSURE SPECIFICATIONS AND CHECK POINTS.................................................................... 106
2.5 TRANSMISSION COOLER ............................................................................................................... 108
2.6 HYDRAULIC DIAGRAM .................................................................................................................... 109
2.7 OPERATION...................................................................................................................................... 110
2.8 POWER FLOWS................................................................................................................................ 117
2.9 GEAR AND CLUTCH LAY OUT ........................................................................................................ 132
2.10 TRANSMISSION REMOVAL AND INSTALLATION........................................................................ 133
2.11 TRANSMISSION COMPONENTS................................................................................................... 137
2.12 DISASSEMBLY AND ASSEMBLY................................................................................................... 155
2.13 SPECIAL TOOLS............................................................................................................................. 264
2.14 FAULT FINDING.............................................................................................................................. 265
2.15 FAULT FINDING.............................................................................................................................. 267
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1.
POWERSHUTTLE TRANSMISSION TURNER MODEL COM-T4-2025
This transmission is used on powershuttle loader

backhoe models 580SR / 580SR+ / 590SR.
The transmission consists of a torque converter, an
internal rotor-type hydraulic pump, an oil distributor,
a solenoid control valve assembly, two hydraulically
operated clutches, a 4-speed synchromesh
geartrain, transmission case and oil cooler tubes.
NOTE: a conventional clutch is not used with this

transmission.
The transmission case serves as an oil tank for the
torque converter and hydraulic clutch assemblies.
The transmission receives power from the engine (1)
by a fluid coupling in the torque converter (2) and hydraulic clutch assemblies in the transmission (3).
1.1
SPECIFICATIONS
GEAR RATIO
Forward
Reverse
4.824
2.998
1.408
0.792
4.020
2.496
1.173
0.660
COLD START BY-PASS VALVE SPRING

Free length.......................................................................................................................... 53.4 mm 0.96 mm
FORWARD CLUTCH SPRING
Free length............................................................................................................................................ 76.6 mm
CLUTCH PISTON SPRING
Free length............................................................................................................................................ 75.9 mm
DETENT SPRING
Free length (Approximately)................................................................................................................ 42.06 mm
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END FLOAT
Input forward Primary Shaft ...................................................................................................... 0.0508-0.41 mm
Input reverse Primary Shaft ...................................................................................................... 0.0508-0.41 mm
Output shaft................................................................................................................ 1st Gear - 0.33-0.508 mm
..................................................................................................................................2nd Gear - 0.35-0.558 mm
...................................................................................................................................3rd Gear - 0.38-0.838 mm
...................................................................................................................................4th Gear - 0.20-0.558 mm
4WD Shaft................................................................................................................................... 0.050-0.28 mm
Bearing End Floats.................................................................................................................... 0.025-0.076 mm
Bearing End Float Shims available ................................................... 0.050/0.076/0.127/0.177/0.381/0.508 mm
HYDRAULIC TESTS
Cold start valve (for reference only) .......................................................................................................... 26 bar
System pressure test .....................................................................................................................13.7-15.2 bar
Torque converter....................................................................................................................................7-11 bar
Reverse Clutch...............................................................................................................................13.7-15.2 bar
Forward Clutch...............................................................................................................................13.7-15.2 bar
4WD Supply ................................................................................................................................... 13.7-15.2 bar
COOLER FLOW TEST
Oil temperature 80-85 C ..................................................... Rpm .................................................. Oil flow l/min
...............................................................................................700 .......................................................12.5 litres
.............................................................................................1000 .......................................................18.2 litres
.............................................................................................1500 .......................................................22.1 litres
.............................................................................................2000 .......................................................24.0 litres
.............................................................................................2200 .......................................................24.5 litres
.............................................................................................2500 .......................................................25.0 litres
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1.2
MOUNTING SCREW TORQUE
Strainer bolts.................................................................................................................................... 18 to 31 Nm
Pump retaining bolts ........................................................................................................................ 18 to 31 Nm
Output Yoke bolts ............................................................................................................................ 68 to 88 Nm
Pressure test plugs ..........................................................................................................................41 to 54 Nm
Main transmission case bolts........................................................................................................... 45 to 64 Nm
Shift detent plug ............................................................................................................................... 41 to 54 Nm
Shift fork screws............................................................................................................................... 18 to 25 Nm
Shift lever assembly screws.............................................................................................................16 to 24 Nm
Drain plugs....................................................................................................................................... 34 to 54 Nm
Relief valve ......................................................................................................................................23 to 30 Nm
Pressure regulator valve .................................................................................................................. 46 to 60 Nm
Cold start valve ................................................................................................................................ 46 to 60 Nm
4WD solenoid valve spool................................................................................................................ 20 to 27 Nm
4WD Solenoid coil retaining nut...............................................................................................................5.4 Nm
Control valve retaining screws ....................................................................................................... 6.8 to 8.5 Nm
4WD hydraulic pipe connections.................................................................................................. 6.8 to 10.2 Nm
Filter housing bolts...........................................................................................................................45 to 64 Nm
Oil filter...............................................................................................................................................7 to 10 Nm
Temperature sender ........................................................................................................................ 20 to 27 Nm
RECOMMENDED SEALANTS
Transmission case joint ................................................................................................................... Loctite 5203
4WD Output gear ...............................................................................................................................Loctite 649
4WD gear (Permanent 4WD assy) ....................................................................................................Loctite 649
4WD clutch supply pipe .....................................................................................................................Loctite 542
Gear lever housing...................................................................................................................Loctite 5900 RTV
Shimming access plug .......................................................................................................................Loctite 649
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1.3
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TRANSMISSION CONTROLS
4x4 POWERSHUTTLE TRANSMISSION CONTROLS
1. GEAR LEVER: it is possible to select four forward and four rearward travel gears.
2. TRANSMISSION DISCONNECT BUTTON: prior to changing gear depress and hold down this
switch which disengages transmission drive, select the required gear with the gear lever and release the switch to re-engage drive.
3. LOADER ATTACHMENT CONTROL LEVER
4. TRANSMISSION DISCONNECT BUTTON: (on
loader attachment control lever) this button is
used to disengage the transmission in order to
increase loader attachment power.
1
5. ROLLER FOR THE PROPORTIONAL CONTROL OF LOADER BUCKET 4x1
6. POWERSHUTTLE TRANSMISSION DIRECTION LEVER: the movement of this lever from
the neutral position will engage the forward or
reverse travel.
NOTE: in reverse gear an audible alarm device
sounds.
7. HORN BUTTON
8. MECHANICAL DIFFERENTIAL LOCK PEDAL:
pressing this pedal enables the differential lock
by locking the two rear wheels together, thus
balancing the drive; they unlock when the torque
of the two wheels are the same or when the
brake pedal is deeply pressed.
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Transmission
The transmission is fully synchronised providing four
forward and four reverse speeds allowing gear ratio
changes on the move. A torque converter is used to
connect the engine to the transmission and the column mounted powershuttle lever (4) enables shifts
between forward and reverse travel without disengaging gear ratios.
A device for transmission disconnect is activated
by pushing button (2), placed on the gearshift lever
(1) or by pushing button (5), placed on the loader
control lever (3).
S WARNING
Always apply the parking brake whenever the machine is parked as the machine is free to roll even
though the transmission gearshift lever and power
reversing lever may be In Gear and the engine is
turned OFF.
Gearshift lever
The single gearshift lever (1) is used to select any
one of the four gear ratios. The transmission disconnect button (2) is depressed and held as the lever is
shifted from one gear to another and then released
to re-connect transmission drive.
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Forward/reverse powershuttle lever

To select FORWARD travel, engage the required
gear ratio with the gearshift lever, then with the engine idling lift the powershuttle lever from the neutral
lock position (1) and move to the forward position (2).
Use the accelerator pedal to control the engine rpm
and the ground speed.
To reverse the direction of travel, reduce engine
speed and move the power reversing from neutral
lock position (1) and rearwards (3) for reverse travel
an audible alarm device sounds.
NOTE: the powershuttle lever is equipped with a
neutral lock to prevent inadvertent engagement of
the transmission. With this design, the powershuttle
lever moves through a T slot to the forward or reverse positions.
IMPORTANT: when operating at low environmental
temperatures with cold transmission oil, allow the oil
to warm up before attempting to shift the powershuttle lever. The transmission can be shifted normally
after the oil warms up.
NOTE: the audible alarm sounds if the powershuttle
lever is operated (forward or reverse) with the parking brake engaged.
NOTE: the powershuttle lever can be shifted at any
engine speed, however, for safe, smooth operation
the engine speed should be reduced to approximately 1200 rpm. This action is easily controlled by using
the foot accelerator to control engine and ground
speed.
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Transmission disconnection
The 4x4 transmission provides for easy upward and
downward gear ratio changes on the move. However, as a clutch is not used between the engine and
transmission, the power flow from the engine to the
transmission must be interrupted to shift from one
gear ratio to another. This is accomplished by using
a transmission disconnect (dump) button.
The finger operated button (2) on the main gearshift
lever knob (1) is easy to operate.
S WARNING
To avoid personal injury do not use the disconnect
switch control to coast down hill. Excessive speed
may cause loss of control, personal injury to a bystander or failure of the transmission.
To make upward gear ratio changes simply depress
and hold the button (2) on the gearshift lever (1),
while moving the lever from one gear ratio to another. When the desired gear ratio has been selected
release the button and allow the unit to gain engine
speed and ground speed. If another higher ratio is required repeat the procedure.
IMPORTANT: to prevent possible damage to the
transmission hydraulic clutches, never use the disconnect switch for inching the machine forward.
Inching the machine forward with the button will
cause the clutches to slip excessively and overheat.
To make downward gear ratio changes or reduce
ground speed, simply lower the engine speed, depress and hold the gearshift lever button and downshift the transmission.
When the desired gear ratio has been selected release the button and adjust the engine speed to suit
ground speed required.
Operating the machine in a too high gear or under a
too heavy load will cause the torque converter to slip
excessively and overheat. If the machine is overloaded, the engine speed will not exceed a range of
1800-2200 rpm at maximum accelerator and the
torque converter will stall bringing the machine to a
complete stop.
If stall does occur, there is still sufficient engine
power to operate the loader however, to prevent the
transmission from overheating, either reduce the
load on the machine or select a lower gear ratio.
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IMPORTANT: operating at a stall for more than 20

seconds can cause the transmission to overheat and
can possibly damage the transmission. If the transmission overheats, the indicator needle (1) moves to
the red zone. Shift both the powershuttle lever and
the gearshift lever to neutral. Idle the engine at 1000
rev/min. until the transmission oil is cooled sufficiently for the indicator needle to drop into the green zone.
Once done, operations may resume.
DIFFERENTIAL LOCK PEDAL (MECHANICAL)

In conditions inducing wheel slip, hold down the differential lock pedal (1) with your heel until the differential lock engages. The lock will automatically
disengage when traction at the rear wheels equalizes. If a rear wheel spins at speed, reduce the engine
speed to idle before engaging the differential lock to
minimize shock loads on the rear axle.
S WARNING
Never use the differential lock at speeds above 8 km/
h or when turning the machine.
When engaged the lock will prevent the machine
turning and personal injury could result.
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1.4
11
LUBRICATION
To ensure proper lubrication and operating temperatures it is most important that appropriate lubricants are
used and that the correct oil level is maintained.
Oil level checking
The oil level should be checked daily and corrected if necessary.
The oil level must be checked with the engine idling and with the transmission oil cold.
In this condition the oil level should fall between the maximum and minimum marks on the dipstick.
At normal operating temperature, (80 C) the oil level will rise to 20 - 30 mm above the maximum mark on the
dipstick.
Do not overfill the transmission as this may result in oil breakdown due to excessive heat and aeration from the
churning action of the gears. Early breakdown of the oil will result in heavy sludge deposits that block oil ports
and build up on splines and bearings. Overfilling may also cause oil leaks.
Oil changes
An initial oil change and flush is recommended after the transmission is placed in actual service.
This change should be made at any time following 50 hours in service, but should not exceed 100 hours.
When changing the oil it is essential to renew the oil filter and clean out the suction strainer.
The object in draining the oil is to eliminate possible bearing surface abrasion and attendant wear. Minute particles of metal, the result of normal wear in service are deposited in and circulated with the oil. Oil changes are
best carried out when the transmission is thoroughly warm.
S WARNING
To prevent oil starvation and possible seizure of the transmission whilst towing the vehicle, it is imperative that
the propeller shafts are disconnected.
Failure to observe this precaution may result in extensive damage to the transmission.
Oil capacity: 18 litres
Suggested oil:
10W or 10W30 Grade mineral oils or automatic transmission fluids which meet at least one of the following
specifications are allowable for use in ambient temperatures of between -20 and 40 C:
Akcela Nexplore MAT3525.
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1.5
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TRANSMISSION OIL FLOW AND SUPPLY
F29967
Pressure oil
Disengaged
Lubrication
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OIL FLOW AND SUPPLY IN NEUTRAL POSITION
16
15
14
7
13
12
11
10
F29968
Pump pressure
Return to Sump
Torque converter flow
1. Powershuttle control solenoid valve oil 14 bar.
2. Torque Converter - Receives low pressure system oil at maximum 10 bar and returns oil to port
(10).
3. Backhoe Boom Lock oil flow 14 bar.
4. Pressure filter - Mounted to the left of the transmission viewed looking forward.
5. FWD - Low pressure system oil supply received
from the filter at 14 bar and fed by external tube
to rear of transmission to the FWD.
Lubrication
Suction
6. Cold start pressure protection valve - prevents
system pressure exceeding 26 bar at initial cold
start.
7. Oil Pump Port OUT, to oil filter assembly
through internal drillings.
8. Oil returned from the oil cooler lubricates shafts,
gears and bearings and returns oil to tank.
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OIL FLOW AND SUPPLY IN FORWARD POSITION
16
15
14
7
13
12
11
10
F29969
Pump pressure
Return to Sump
Torque converter flow
1. Returned lubrication oil from the pump shaft
bush to tank.
2. Torque Converter oil supply IN, received at
maximum 10 bar.
3. Transmission tank/system capacity: 17 litres
(2WD) 18 litres (4WD).
4. Oil Cooler - Mounted below the engine coolant
radiator.
5. Oil pump suction port IN, from the tank.
Lubrication
Suction
6. Torque Converter oil OUT, to oil cooler.
7. Torque Converter pressure regulating valve, receives oil from the sequencing valve (16) and
returns oil in excess of 10 bar to tank.
8. System pressure sequencing valve - Maintains
system oil at 14 bar and supplies a continuous
oil feed to the torque converter regulating valve.
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15
TRANSMISSION OIL SUPPLY PORT
Viewed from front and rear housings

1. Oil supply port to reverse clutch pack, rear casing.
2. Oil supply port to forward clutch pack, rear casing.
3. Oil supply port to pressure test reverse clutch
pack.
4. Oil supply port too pressure test forward clutch
pack.
5. 4WD solenoid.
6. System pressure test point, connected to test
block.
7. Locating dowel.
8. Cold start oil pressure protection valve.
9. Torque converter pressure test point, connected
to test block.
10. System pressure sequencing valve.
11. Torque converter pressure regulating valve.
12. Oil supply from pump to solenoid valve pack.

13. Oil supply port to reverse clutch pack, front casing.
14. Oil port to tank (dump) from solenoid.
15. Oil supply port to reverse clutch pack, front casing.
16. Oil supply port to forward clutch pack, front casing.
17. Oil supply port to forward clutch pack, front casing.
18. Manufacturing drilling only.
19. Forward oil supply port (front casing).
20. Forward oil supply port (rear casing).
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TRANSMISSION OIL FLOW THROUGH SOLENOID VALVE

The forward (1) or reverse (2) solenoid valves fitted
at the top of the transmission housing control the oil
flow to the forward and/or reverse clutch packs in the
transmission.
On the underside of the solenoid valve are the 4

ports for directional oil flow to and from the solenoid
valve.
1. Oil supply from the valve to the forward clutch
pack
2. Return oil to tank
3. Oil supply from the valve to the reverse clutch
pack
4. Oil supply from the pump into the valve
5. Locating pin
When the powershuttle lever in the cab is in neutral

position the solenoid valve spool (1) will be static and
oil (2) will not flow into either reverse (3) or forward
(4) clutch pack oil gallery.
When forward direction is selected on the powershuttle lever the solenoid valve spool (1) will move to
the left (as shown) and the oil (2) will flow into the forward clutch pack oil gallery (4).
When reverse direction is selected on the powershuttle lever the solenoid valve spool (1) will move to
the right (not shown) and the oil (2) will flow into the
reverse clutch pack oil gallery (3).
F29973
F29974
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17
OIL FLOW SOLENOID CONTROL VALVE OPERATION (FORWARD DRIVE ONLY SHOWN)
The solenoid valve when in neutral position dead
heads the oil flow at the spool (1) from the supply
port and no oil is allowed to pass through the valve.
Therefore the oil in the galleries beyond the spool at
the fill time metering valve (2) remains static.
2
3
F29975
Selection of the forward / reverse powershuttle lever

in the cab directs a current flow to the forward or reverse solenoid and the spool (1) will move in the direction selected, reverse shown. The oil then flows
past the spool to the clutch pack and applies pressure to the fill time metering valve (2), a small bore
allows oil to flow into the clutch feathering valve.
When valve (2) moves it partially uncovers a port to
the tank and also opens the control orifice within the
valve. Therefore a precisely metered flow of oil is fed
to the pressure regulating (feathering) piston (3). As
this piston is pushed back against its spring the pressure at the clutch builds up gradually to give a
smooth jerk free clutch engagement.
2
3
F29976
When the piston reaches the end of its travel, clutch

pressure quickly builds up to full system pressure either side of valve (2) so the light spring pushes the
valve covering the port to the tank.
The oil is dead headed at system pressure at the
clutch so ensuring full torque can be transmitted by
the clutch.
2
3
F29977
NOTE: the control valve also includes a pressure

regulating (feathering) valve and a fill time metering
valve for the reverse clutch pack.
Regulated pressure oil

Return oil
Pressure oil
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1.6
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TRANSMISSION HYDRAULIC VALVES AND PRESSURE TEST POINTS
NOTE: all pressure test ports are 9/16 in UNF thread

size.
1. Cold start oil pressure relief valve
26 bar reference only
2. Forward travel solenoid valve
13.7-15.2 bar
3. Test port for reverse clutch pack
13.7-15.2 bar
4. Test port for forward clutch pack
13.7-15.2 bar
5. System pressure sequencing valve
13.7-15.2 bar
6. Oil flow OUT to cooler
7. Oil OUT to cooler, test port
6.5 bar
8. Front wheel drive test point
13.7-15.2 bar
9. Oil flow IN from cooler

10. Torque converter pressure regulating valve
7-11 bar
11. Oil in from cooler, test port
3.5 bar
12. Backhoe attachment boom lock supply
13.7-15.2 bar
13. System pressure test point
13.7-15.2 bar
14. Converter pressure oil test port
7-11 bar
15. Front wheel drive solenoid
13.7-15.2 bar
16. Oil filter
17. Reverse solenoid valve
13.7-15.2 bar
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1.7
TRANSMISSION POWER FLOW
When neutral is selected on the powershuttle lever

(1), the transmission forward (3) and reverse hydraulic clutch packs or (4) are free to rotate and hence
there is no drive in the transmission.
With forward or reverse selected on the powershuttle
lever (1) power will be directed through the clutch
packs (3) or (4) to the gear train and selection of gear
on lever (2) will result in engagement of gears to the
output shafts.
Power for all four forward gear ratios is transmitted
from the front hydraulic clutch (3) on the input shaft.
The input shaft then transmits power to the counter
shaft forward gear and the countershaft in turn transmits power to the output shaft.
Power flow for all four reverse gear ratios is the same
as for all four forward gear ratios except that the rear
clutch (4) is engaged to transmit power to the reverse
idler gear. The reverse idler gear in turn transmits
power to the gear on the countershaft and in turn
transmits power to the output shaft.
Because power is being transmitted through the reverse idler gear, the countershaft and output shaft
will rotate in the opposite direction as for forward
gear ratios. The rear input shaft will also rotate in the
opposite direction.
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F29980
Input
Intermediate
Output
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NOTE: 4WD shown.
21
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NOTE: 4WD version shown.
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1.8
23
TRANSMISSION 2WD COMPONENTS
F27510
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F27511
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67.
Front gear case assembly

Rear gear case assembly
Plug and O-ring
Cold start spring housing
Screw
Sealing cap
Screw
Reverse shift hub sleeve
Synchronizer assembly
Ring seal
Copper washer
Thrust bearing
Thrust washer
Ball
Cold start spring
O-ring
Plug
Oil filter housing
Flywheel housing
Washer
Filter housing gasket
Screw
Cover plate
Adjuster screw
4th gear output shaft
3rd gear output shaft
2nd gear output shaft
1st gear output shaft
Spacer
Bearing
1st gear bearing spacer
1st gear bearing sleeve
Circlip
Expansion plug
Directional valve
O-ring
4th gear thrust washer
Bearing spacer
Shim
Shim
Bearing
Output shaft
Bearing
Bearing spacer
Shim
Shim
Support washer
Bearing
Bearing
Thrust washer
Countershaft
Reverse idler gear
Input shaft assembly
Forward primary gear
Reverse primary gear
68. Clutch pack retaining clip

69. Clutch pack retaining plate
70. Clutch plate
71. Clutch plate (friction)
72. Circlip
73. Spring retainer
74. Piston return spring
75. Piston
76. Piston sealing ring outer
77. O-ring
78. Piston sealing ring inner
79. O-ring
80. Breather plug
81. Capscrew
82. Breather
83. Needle bearing spacer
84. Screw
85. Bearing - needle
86. Temperature sender
87. Output yoke washer
88. O-ring
89. Screw
90. O-ring
91. End yoke assembly
92. Pump assembly
93. Pump sealing ring
94. O-ring
95. Detent ball
96. Detent spring
97. 1st/2nd shift fork
98. 3rd/4th shift fork
99. 1st/2nd shift rod
100.3rd/4th shift rod
101.Shift fork screw
102.Gearshift lever
103.Screw
104.Gear lever seating
105.Pin
106.Rubber boot
107.O-ring
108.Suction strainer
109.Pressure regulator valve
110.Plastic clip
111.Plastic clip
112.Plug
113.Converter relief valve
114.Adjuster screw
115.Oil seal
116.Oil filter
117.Oil filter adapter
118.Drain plug
120.Dowel
121.Strainer cover plate
127.Plug
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1.9
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TRANSMISSION 4WD COMPONENTS
F27512
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53.
54.
55.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
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Front gear case assembly

Rear gear case assembly
Plug assembly
Screw
Screw
Screw
Reverse shift hub sleeve
Synchronizer assembly
Sealing ring
Copper washer
Thrust bearing
4WD piston sealing ring
Support washer
Torque converter
O-ring 4WD piston
Circlip
Clutch collar
Spring 4WD
Spring support
Flywheel housing
Parking brake assembly
4WD shaft
4WD gear
Converter drive plate
Thrust washer
4th gear output shaft
3rd gear output shaft
2nd gear output shaft
1st gear output shaft
4WD gear output shaft
Bearing 1st gear output shaft
Bearing spacer
Bearing sleeve
Circlip
Sealing ring 4WD shaft
Bearing spacer
Shim
Shim
Thrust washer
Bearing spacer
Shim
Shim
Bearing
Output shaft
Bearing
Bearing spacer
Shim
Shim
Bearing
Bearing
Bearing
Thrust washer
Countershaft
Reverse idler gear
Input shaft assembly coaxial
Forward primary gear
Reverse primary gear
Clutch pack retaining ring
Clutch pack retaining plate
70. Clutch plate - steel

71. Clutch plate - friction
72. Circlip
73. Spring retainer
74. Piston return spring
75. Clutch piston
76. Piston sealing ring
77. O-ring
78. Piston sealing ring
79. O-ring
80. Brake caliper bolt
81. End yoke
82. Spacer ring
83. Needle bearing spacer
84. Screw
85. Bearing - needle
86. Bearing
87. Output flange washer
89. Screw
90. O-ring
91. Brake flange assembly
92. Pump assembly
93. Sealing ring
94. Sealing ring
95. Detent ball
96. Detent spring
97. 1st/2nd shift fork
98. 3rd/4th shift fork
99. 1st/2nd shift rod
100.3rd/4th shift rod
101.Shift fork screw
102.Gear stub lever
103.Screw
104.Gear lever seating
105.Pin
106.Rubber boot
107.Washer
109.Hydraulic pipe nut
110.Plastic clip
111.Plastic clip
112.Plug
113.Converter relief valve
114.Adjuster screw
115.Banjo bolt washer
116.4WD clutch supply pipe
118.Drain plug assembly
119.Hydraulic pipe sleeve
120.Bearing spacer
121.Shim
124.Shim
125.Cold start spring housing
126.Coaxial drive shaft
127.Capscrew
128.Pressure regulator valve
129.4WD solenoid
130.Directional control valve
131.Oil filter
132.Oil filter adapter
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134.Dowel
135.Oil seal
136.Sealing cap
137.Suction strainer
138.O-ring suction strainer
139.Support washer
140.Strainer cover plate
141.Adjuster screw
142.Breather
143.O-ring
146.O-ring
149.Expansion plug
150.Brake caliper nut
151.Pump mounting stud
152.Oil filter housing
153.Filter housing gasket
154.Screw
155.O-ring
156.Cold start spring
157.Ball
158.Adjuster screw
160.Adjuster screw
161.Copper washer
162.Screw
163.Remote test port assembly
164.Remote test port pipe
165.Remote test port pipe
168.Pump mounting stud nut
170.4WD gear bearing
171.Spacer 4WD gear bearings
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SOLENOID VALVE COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Solenoid retainer
Dust seal
Solenoid
Washer
Solenoid body
Guide
Spring
Solenoid pin
Seal
Support body solenoid
End cap
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Circlip
Clutch fill metering valve
Spring
Spool
Piston clutch fill
Spring
Retainer
Spring
Seal
Plug
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1.10 TRANSMISSION REMOVAL

Remove the transmission and engine as a complete
unit from the vehicle and place on a suitable stand for
disassembly.
NOTE: prior to disassembly drain the oils into suitable containers for disposal.
Prior to separating the transmission from the engine.
Remove the starter motor (1).
Engine timing tab (2).
Torque converter back plate attaching bolts through
the starter motor aperture (1).
Bell housing attachment bolts (3).
IMPORTANT: prior to positioning the transmission
vertically remove the vehicle system oil pump (4) and
torque converter unit (5) from the transmission bell
housing (3).
Using eye bolts (1), one on each side capable of lifting a weight of 250 kg hoist the transmission vertically and place in a safe, clean and suitable workshop
environment.
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1.11 DISASSEMBLY AND ASSEMBLY

TRANSMISSION DISASSEMBLY
Invert the transmission on a suitable bench.
For convenience the bench top should have a hole
in it to accommodate the input shaft and pump. Remove 3 screws and withdraw the gearshift lever assembly.
Remove the plastic plugs and 4 cap screws and

withdraw the direction control valve.
Remove the converter relief valve.
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Remove the pressure regulator valve.
Remove the cold start housing, the spring and the

ball.
Remove the temperature sender.
Remove the bolt, the washer and the O-ring and

withdraw the output yoke.
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Remove the screw, the washer, the O-ring and extract the 4WD yoke and the spacer (on 4WD models
only).
Remove 17 screws and using a suitable hoist take

off the rear transmission case.
Lever slots are provided to assist removal.
NOTE: the bearing cones and shims may fall from
the rear case during removal.
IMPORTANT: for proper reassembly, take note and
mark which bearings and shims come from which locations.
Remove the 4WD shaft assembly (on 4WD models

only).
Tilt the countershaft and withdraw the input shaft assembly.
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Remove the reverse idler shaft assembly.
Remove the by-pass plug, the spring and the ball.
Ensure both synchronizers are in the neutral position then remove the 1st/2nd shift fork screw.
Withdraw the 1st/2nd shift rod from the housing.

Then using a magnetic probe remove the interlock
ball from the detent, bore.
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Remove the 3rd/4th shift fork screw.

NOTE: before attempting to remove the 3rd/4th shift
rail, replace the detent plug as the ball and spring
may shoot out and cause injury.
Turn the 3rd/4th shift rod through 90 and withdraw

from the housing.
Remove the detent plug, the inner detent ball and

the spring.
Remove the counter shaft assembly.
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Remove the 1st/2nd and 3rd/4th shift forks.
Remove the output shaft front assembly.
Remove the 4th gear lock out screw (if fitted).
Remove 2 screws and withdraw the strainer cover,

the O-ring, the spacer and the strainer.
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Using a strap wrench remove and discard the oil filter.
Remove 2 bolts and take of the oil filter housing and

the gasket.
Remove the 4WD solenoid coil and the retaining nut

(on 4WD models only).
Remove the 4WD solenoid spool (on 4WD models

only).
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Remove and discard the expansion plug from the

shimming access hole.
Invert the case. Remove 4 screws and copper washers then withdraw the pump assembly and the sealing ring.
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INPUT SHAFT DISASSEMBLY

Position the shaft in a soft jawed vice as shown.
Remove and discard the 3 sealing rings.
Using the appropriate bearing puller 380002683 remove the rear bearing.
Remove the thrust washer and needle bearing.
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Remove the reverse primary gear.
Remove the bearing, the spacer, the bearing and

the thrust washer.
Remove the clutch pack retaining ring.
Remove the clutch pack retaining plate.
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Remove the clutch pack.
Using the appropriate tool 380002689 compress the

piston spring and release the circlip.
Replace the spring, the retainer and the circlip.
Using pliers, as shown, pull the piston out of the

drum.
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Invert the shaft and remove the sealing ring.

Repeat steps described above to dismantle the forward clutch pack.
Remove and discard the piston sealing rings and the

O-rings.
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INPUT SHAFT ASSEMBLY

Re-new the piston sealing rings and the O-rings.
To assist assembly bend the inner sealing ring into
a heart shape as shown.
Using transmission fluid to lubricate the seals push

the piston into the drum.
Using the tool 380002689 compress the spring and

locate the circlip into its groove.
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Replace an externally splined (plain) disc and then

an internally splined (friction) disc alternately until six
of each have been replaced.
Replace the clutch pack retaining plate and refit the

retaining clip.
Replace the thrust washer, the bearing, the spacer

and the bearing.
Line up the clutch plate splines and replace the primary gear. Remove the needle bearing and the
thrust washer.
NOTE: the needle bearing should be fitted with the
closed side of its cage against the gear.
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Using an appropriately sized tube replace the bearing.
Invert the shaft and repeat previous operation. Then

fit a new sealing ring as shown.
Finally fit 3 new sealing rings to the rear of the shaft

as shown. (To avoid damage the sealing rings
should be left off until all shimming operations have
been completed).
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DISASSEMBLY AND ASSEMBLY OF THE

COUNTERSHAFT
The countershaft assembly.
Using the appropriate bearing pullers 380002691

and 380002687 remove the countershaft front and
the rear bearings.
Using an appropriately sized tube replace the countershaft front and the rear bearings.
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DISASSEMBLY AND RE-ASSEMBLY OF THE

REVERSE IDLER SHAFT
The reverse idler assembly.
Using the appropriate bearing puller 380002683 remove the front and the rear bearings.
Using an appropriately sized tube replace the front

and the rear bearings.
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OUTPUT SHAFT DISASSEMBLY

Position the shaft assembly in a soft jawed vice as
shown.
Using the appropriate bearing puller 380002686 remove the front bearing.
Refit the 4th gear and the thrust washer.
Remove the 3rd/4th synchro assembly.
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Remove the circlip and the synchro hub.
Remove the 3rd gear.
Invert the shaft and using the appropriate bearing

puller 380002687 remove the rear bearing.
Remove the 4WD gear (on 2WD models, a spacer is

fitted instead of the gear).
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Remove the 1st gear.
Remove the needle bearings and the spacer.
Remove the 1st/2nd synchronizer assembly.
Using a suitable bearing puller or press.

Remove the bearing sleeve, the synchro hub and
the 2nd gear.
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Remove the bearing sleeve, the synchro hub and

the 2nd gear.
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OUTPUT SHAFT ASSEMBLY

Replace the 2nd gear and the synchro hub.
Using an appropriately sized tube refit the 1st gear

bearing sleeve.
Replace the 1st/2nd synchronizer assembly.
Replace the 1st gear needle bearings and the spacer.
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Replace the 1st gear.
Replace the 4WD gear using Loctite 649 spline lock

or equivalent.
NOTE: assemble the gear with the splined bushing
against the 1st speed gear (on 2WD models, a spacer is fitted instead of the gear).
Using an appropriately sized tube refit the rear bearing.
Invert the shaft and refit the 3rd gear, the synchro
hub and the circlip.
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Refit the 3rd/4th synchronizer assembly.
Refit the 4th gear and the thrust washer.
Using an appropriately sized tube replace the front

bearing.
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HYDRAULIC DOG CLUTCH 4WD DISASSEMBLY

The hydraulic dog clutch 4WD assembly.
Position the shaft in a soft jawed vice and remove

the sealing ring.
Remove the thrust washer.
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Remove the 4WD gear.
Remove the two needle bearings and the spacer.
Invert the shaft and using the appropriate bearing

puller 380002685 remove the front bearing.

spring and release the circlip.
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Remove the piston drum assembly.
Remove the piston seal and the O-ring from the

shaft and discard.
Remove and discard the piston seal and the O-ring

from the piston drum.
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HYDRAULIC DOG CLUTCH 4WD ASSEMBLY

Fit a new O-ring and sealing ring to the shaft.
Fit a new O-ring and sealing ring into the piston.

Bend the sealing ring into a heart shape as shown to
assist assembly.
Lubricate the seals with a light grease and refit the

piston to the shaft.
Replace the piston spring and the clip retainer.
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spring and retainer and refit the circlip.
Using an appropriately sized tube refit the front bearing.
Invert the shaft and refit the two needle bearings and
spacer as shown.
Replace the 4WD gear.
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Replace the thrust washer.
Using an appropriately sized tube replace the rear

bearing.
Fit a new seal ring. (To avoid damage the sealing

ring should be left off until all shimming operations
have been completed).
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PERMANENT 4WD SHAFT ASSEMBLY

The permanent 4WD shaft.
Using the appropriate bearing puller 380002685 remove the front and the rear bearings.
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PERMANENT 4WD SHAFT ASSEMBLY

Replace the 4WD gear using Loctite 649, or equivalent, on the shaft splines.
Then using a suitably sized tube refit the front and
the rear bearings.
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HYDRAULIC MULTI PLATE CLUTCH 4WD SHAFT

DISASSEMBLY
The hydraulic multiplate clutch 4WD shaft assembly.
Mount the shaft assembly in a suitable soft jawed

vice and remove the rear sealing ring.
Remove the thrust washer and the thrust bearing.
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Remove the needle bearings and the spacer.
Remove the needle bearing and the thrust washer.
Remove the clutch pack retaining clip.
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Remove the clutch pack retaining plate.
Remove the clutch pack.

piston return spring and release the circlip.
Remove the clip retainer and the spring.
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Remove the piston from the drum.
Remove and discard the piston sealing rings.
Invert the shaft and remove the front bearing using

the appropriate tool 380002685.
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HYDRAULIC MULTI PLATE CLUTCH 4WD SHAFT

ASSEMBLY
Using an appropriately sized tube refit the front bearing.
Replace the piston sealing rings to facilitate assembly: the seals may be warmed in lukewarm water prior to assembly.
NOTE: the outer seal must be fitted with the open
edge facing away from the clutch pack.

piston sealing rings. The seals should be left in the
tool 380002684 for a minimum of 30 minutes prior to
assembly into the clutch drum.
Lubricate the seals with a light grease and refit the

piston into the clutch drum. Then replace the spring,
retainer and circlip.
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piston return spring and locate the circlip into its
groove.
Replace an externally splined (plain) disc then an internally splined (friction) disc alternately until 8 plain
discs and 8 friction discs have been fitted.
Replace the retaining plate and fit a new retaining

clip.
Refit the thrust washer and the needle bearing.
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Refit the 4WD gear.
Refit the needle bearings and the spacer.
Refit the needle bearing and the thrust washer.
Using an appropriately sized tube refit the rear bearing.
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Refit a new sealing ring and lubricate with a light

grease. (To avoid damage the sealing ring should be
left off until all shimming operations have been completed).
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THE OIL PUMP DISASSEMBLY AND ASSEMBLY

Individual components of the oil pump are non serviceable. The pump may, however, be stripped for
cleaning and examination purposes.
View showing a dismantled pump assembly.
The pump oil seal may be replaced using an appropriately sized tube.
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DIRECTION CONTROL VALVE DISASSEMBLY

AND ASSEMBLY
Disassembly of the control valve is not generally recommended as, with the exception of the solenoids,
individual parts are non serviceable. It may however
be dismantled for cleaning and examination.
The valve fitted may be either the modulated type or
the non-modulated type.
The retaining nut, coil and washer removed.
The modulation components removed.
There are 4 O-rings fitted to the underside of the

valve which may be renewed if necessary.
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GEAR LEVER HOUSING DISASSEMBLY AND

ASSEMBLY
Remove the plastic ties from the rubber gaiter and
pull the assembly apart.
Before re-assembly remove all traces of old sealant

from the joint faces.
Apply a bead of RTV joint compound (Loctite 5900)

to the sealing face.
Lubricate the ball seating with a light grease and

push the two halves of the assembly together. Secure the rubber boot with two new plastic ties.
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TRANSMISSION ASSEMBLY
All nylon patch bolts may be re-used 5 to 6 times provided a prevailing thread torque of 20 to 25 Nm is recorded.
All shafts and bearings should be lubricated with
transmission fluid prior to assembly.
To prevent possible contamination of hydraulic parts
lint or cotton rags should not be used.
Position the front case as shown and using a suitably sized tube fit a new output shaft oil seal to a
depth of 6 mm below the housing face. Fill the seal
lip with grease (on 4WD models only).
If previously removed, replace the two plug and Oring assemblies and tighten to a torque of 41-54 Nm.
Refit the oil pump assembly and sealing ring. Tighten 4 bolts to a torque of 18-31 Nm.
New copper washers must be fitted under the bolt
heads. Finally check for free rotation of pump rotor.
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Invert the case and then refit the bearing cups if previously removed.
Using a suitable tool push the inner detent spring

and ball into the case and secure in place with a
dummy plug as shown.
Dummy plug in place.
Replace the countershaft and reverse idler shaft assemblies.
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Slide the 1st/2nd fork onto the 3rd/4th rail then refit
the 3rd/4th shift fork and tighten the screw to a
torque of 18-25 Nm. Hold the forks and rail in place
on the output shaft then refit the complete assembly
into the case. The shift rail should displace the dummy plug as it enters the bore.
NOTE: check that the inner detent spring and ball
have not become displaced and remove the loose
dummy plug from the case sump.
Push the interlock ball into the detent bore.
Refit the 1st/2nd shift rail and tighten the shift fork
screw to a torque of 13-18 Nm.
Check that the interlock ball is correctly positioned in
between the two rails.
Replace the outer detent ball and the spring.

Tighten the plug to a torque of 41-54 Nm.
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Remove the 4WD shaft assembly (on 4WD models

only).
Lubricate the rear seal with a light grease.
Lubricate the input shaft front and rear seals with a

light grease and refit the shaft assembly into the
case.
Rear case with all shaft assemblies fitted.
Position the rear case as shown and using a suitably

sized tube fit a new output shaft oil seal to a depth of
6 mm below the housing face. Fill the seal lip with a
light grease.
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Invert the case and replace the shim packs and

bearing cups. The 2 mm thick spacer shim should be
fitted into the case first, then fit the remaining shims
followed by the bearing cup.
A light grease may be used to help hold the cups in
the case.
Refit the rear case, (without sealant at this stage),

and secure with at least 6 equally spaced bolts.
When fitting the rear case be careful to avoid damaging the input shaft sealing rings.
Position a D.T.I. on the end of the input shaft as

shown, and using a suitable pry bar through the side
access hole, measure and note the shaft end float.
NOTE: all shaft assemblies should be rotated several times to seat the bearings prior to measuring the
end float.
Attach a suitable shimming tool 380002693, to the

end of the reverse idler shaft. Position a D.T.I. as
shown, and using a pry bar lift the shaft, then measure and note the end float.
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end of the countershaft.
Position a D.T.I. as shown, and using a pry bar lift
the shaft, then measure and note the end float.

end of the output shaft. Position a D.T.I. as shown,
and using a pry bar lift the shaft, then measure and
note the end float.

end of the 4WD shaft. Position a D.T.I. as shown
and, using a pry bar, lift the shaft, then measure and
note the end float (on 4WD models only).
Remove the rear case and add or remove shims as
necessary to give 0.025 to 0.076 mm end float on all
shafts.
Repeat steps 17 to 22 until all shaft end floats are
correct.
Replace the 4 O-rings in the front case (on 2WD

models, there are only 3 O-rings).
NOTE: the input shaft and 4WD shaft sealing rings
should now be fitted.
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Refit the rear case using an approved liquid gasket

(Loctite 5203) taking care not to damage the input
shaft or 4WD shaft sealing rings. Tighten the 17
bolts to a torque of 45-64 Nm.
Replace the shaft end plug and O-ring assemblies.

Note the special breather plug is fitted in the reverse
idler position. Tighten to a torque of 41-54 Nm.
Fit a new expansion plug to the shimming access

hole using an approved sealant. (Loctite 649).
Replace the output yoke, the O-ring, the washer and

the bolt. Then tighten to a torque of 68-88 Nm.
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Replace the spacer, the 4WD yoke, the O-ring, the

washer and the bolt. Then tighten to a torque of 6888 Nm.
Refit the cold start ball, the spring and the housing.
Then tighten to a torque of 46-60 Nm.
Lubricate the seals with transmission fluid then refit

the pressure regulator valve and tighten to a torque
of 46-60 Nm.
Lubricate the seals with transmission fluid then refit

the converter regulator valve and tighten to a torque
of 23-30 Nm.
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Refit the temperature sender and tighten to a torque

of 20-27 Nm.
Ensure the 4 O-rings are in place then refit the control valve assembly, tighten the 4 cap screws to a
torque of 6.8 to 8.5 Nm. Refit the 4 plastic caps to the
capscrew holes.
NOTE: the valve can only be fitted one way round as
it is located by a small dowel pin.
Refit the strainer, the spacer, the O-ring and the cover plate. Then tighten the two screws to a torque of
18-31 Nm.
Refit the drain plug and the O-ring assembly.

Tighten to a torque of 34-54 Nm.
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Refit the 4th gear lock out screw, (when this feature
is not required a shorter blanking screw is fitted). On
some applications an additional sealing plug may be
fitted.
Apply a bead of RTV joint compound (Loctite 5900)

to the gear case.
Refit the gear lever assembly and tighten the three

Refit the filter housing and gasket. Tighten the two

NOTE: do not use sealant on this gasket as it is
graphite coated.
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Lubricate the seal with a light grease and screw on

a new oil filter. Tighten to a torque of 7 to 10 Nm, or
a half to three quarters of a turn after initial seal contact.
Slightly lubricate the seals and refit the 4WD solenoid valve spool (on 4WD models only).
Tighten to a torque of 20-27 Nm.
Remove the 4WD solenoid coil and the nut (on 4WD
models only). Tighten to a torque of 5.4 Nm maximum.
If previously removed refit the 4WD clutch supply

pipe, apply sealant (Loctite 542) to threads and tighten nuts to a torque of 6.8-10.2 Nm.
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TEST PORT
The transmission oil, should be at an approximate
temperature of 80 C during pressure tests.
All pressure test ports have a 9/16 UNF thread.
Forward, reverse and 4WD clutch pack pressures
should not be more than 1 bar lower than the oil
pump pressure.
Oil pump pressure test port. Pressure should be
13.5 to 15.5 bar at maximum engine speed. (Approximately 2500 rpm).
Reverse clutch pressure test point.

Pressure should be 12.5 to 15.5 bar at maximum engine speed. (Approximately 2500 rpm).
Forward the clutch pressure test point.

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4WD pressure test point.

Converter relief pressure test point.

Pressure should not exceed 7.5 bar at maximum engine speed. (Approximately 2500 rpm).
For Coaxial transmissions max pressure should be
10.5 bar.
Lubrication pressure test point. Pressure should be

0.5 to 2.5 bar at maximum engine speed. (Approximately 2500 rpm).
If a malfunction of the transmission is indicated a
systematic pressure checking procedure should be
followed. These checks should be carried out while
the transmission is still in the vehicle so that true operating conditions are created. Pressure checks are
essential since a failure in the hydraulic system may
not be easily traceable when the transmission is
stripped down on a bench.
All pressure checks should be carried out with the
transmission gear lever in the neutral position, the oil
temperature at 80 to 85 C, and the engine speed
maintained at 2000 to 2500 rpm. As a safety precaution the vehicles parking brake should be applied.
All pressure test ports have a 9/16 UNF thread. A
pressure gauge is required that will measure up to
20 bar.
For test port locations refer to illustrations at page
18.
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PARKING BRAKE
The caliper assembly is mounted directly onto the
rear face of the transmission housing.
1.
2.
3.
4.
A.
Mounting face
Locknut
Mounting bolt
Outer locknut
Adjust the two mounting bolts and locknuts to
leave a 0.25/1.50 mm gap between the locknut
and sleeve.
Then torque locknuts against mounting surface
to 155 Nm.
B. Adjust this nut until pads are in contact with the
brake pads.
Then loosen 1/2 turn.
Finally torque outer locknut to 60-70 Nm.
F27714
IMPORTANT:
BRAKE PAD: the minimum acceptable thickness of
the brake pads is 2.286 mm.
BRAKE DISC: the nominal thickness of the disc is
9.5 mm.
The maximum total wear limit for the disc is
1.524 mm.
Based on the nominal thickness of 9.5 mm this would
give a minimum thickness of 7.976 mm.
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Brake pad replacement

Remove the retaining spring clip.
Withdraw the friction pads.
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1.12 FAULT FINDING

PROBLEM
Transmission fails to drive in
either direction
Transmission drives in one

direction only
Delay in taking up drive
No drive from 4WD
Transmission overheating
Operating in too high of gear

range for conditions
Difficult gear selection
Vehicle moves with direction

valve in neutral position
High stall speed
Low stall speed
CAUSE
Low or no pump pressure.
Low or no oil in transmission.
Mechanical failure in transmission.
Worn or broken input shaft seal rings.
Pressure relief solenoid valve faulty.
Direction control solenoid valve inoperative.
Blockage of restricted flow in oil ports.
Low oil pressure on one clutch pack due to leaks.
Clutch piston seals worn or damaged.
Clutch pack excessively worn.
Direction control solenoid valve or coil faulty.
Worn or broken input shaft seal ring.
Low converter pressure.
Low oil level.
Low clutch pressure.
Faulty modulation in direction control solenoid valve.
Blocked direction control solenoid valve.
4WD solenoid valve or coil not operating.
Low 4WD clutch pack pressure.
Worn 4WD clutch pack.
Oil level too high or low.
Cooler flow restricted.
Low oil pressure.
Clutch packs slipping due to low pressure or wear.
Excessive stall operation.
Shift to lower gear.
Forward or reverse travel clutch pack pressurised when not selected.
Direction control solenoid valve faulty.
Input shaft seal rings leaking.
Forward or reverse travel clutch pack not releasing due to a mechanical
failure.
See Difficult gear selection.
Low oil level. Air in oil.
Clutch plates slipping due to low pressure or wear.
Torque converter faulty.
Converter relief valve faulty.
Wrong torque converter installed.
Poor engine performance.
Torque converter faulty.
Wrong torque converter installed.
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Low pump pressure
High pump pressure

Low forward or reverse clutch
pack pressure
High forward/reverse clutch
pack pressure
Converter pressure low
Converter pressure high
Low 4WD clutch pack

pressure
High 4WD clutch pack

pressure
Low lubrication pressure
Worn or broken pump.

Pump seal ring leaking.
Restricted oil strainer or filter.
Blockage in oil ports between transmission sump and oil pump.
Pressure regulator valve stuck open.
Cold start valve stuck open.
Has normal operating oil temperature been reached?
Direction control solenoid valve faulty.
Piston seal or O-ring leaking.
Input shaft seal ring leaking.
Leak in converter, oil cooler or connection hoses.
Very hot oil.
Blockage or restriction in the oil cooler.
Very cold oil.
4WD piston seals leaking.
4WD shaft seal ring leaking.
Leak from 4WD clutch supply pipe.
Faulty 4WD solenoid valve.
Blockage or restriction in 4WD clutch supply pipe.
Blockage or restriction in the oil cooler.
Input shaft front seal ring leaking.
Very hot oil.
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FAULT DIAGNOSIS MECHANICAL SYSTEM

PROBLEM
CAUSE
Noise
Vehicle driveline problem:

Axles, propshafts, engine, engine mounts.
Misalignment of transmission/engine.
Worn or damaged bearings.
Gear teeth damaged or broken.
Excessive end float of shafts or gears.
Clutch plate failure forward, reverse or 4WD.
Incorrect grade of oil in transmission.
Low oil level.
Gear or thrust washer beginning to seize.
Difficult gear selection
Shift rods worn or bent.

Shift forks worn, loose or twisted.
Synchronizer assemblies worn or damaged.
Clutch pack not releasing due to mechanical fault.
Clutch pack not releasing due to hydraulic fault.
Gearshift lever worn or damaged.
Incorrect grade of oil in transmission.
Low oil level.
Jumping out of gear
Detent springs worn or broken.

Synchronizer or gear dog teeth worn or damaged.
Synchronizer assemblies worn or damaged.
Shift forks worn, loose or twisted.
Restriction or wear in gear linkage or stub lever assy.
not allowing gears to be fully selected.
Excess end float on output shaft assembly or gears.
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1.13 SPECIAL TOOLS

P/N CNH
DESCRIPTION
380002683
Input and reverse idler shaft bearing removal collect
380002684
Piston seal sizing ring (on 4WD models only)
380002685
Removal/installation of the front/rear bearing of the 4WD shaft and of the front bearing
of the coaxial input shaft
380002686
Output shaft front bearing removal collect
380002687
C/shaft and output shaft rear bearing removal collect
380002689
Input shaft spring compressor
380002690
4WD shaft spring compressor (on 4WD models only)
380002691
C/shaft front bearing removal collect
380002692
Coaxial input shaft and hydraulic dog clutch 4WD shaft spring compressor
380002693
Shimming adapter
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2.
POWERSHIFT TRANSMISSION DANA T16000
This transmission is used only on powershift loader backhoe models 580SR+ / 590SR / 695SR.
A
2
3
4
5
6
7
8
1
F27718
2.1
SPECIFICATIONS
HYDRAULIC SPECIFICATIONS
Suitable for operation from ambient to 120 C continuous operating temperature.
Must withstand a 20 bar continuous pressure and a 40 bar variable pressure.
Conform SAE J1019 and SAE J517, 100RI.
Weight ...................................................................................................................................................... 290 kg
BOLT TORQUES
Output flanges............................................................................................................................... 339 - 407 Nm
Filter torque ....................................................................................................................................... 30 - 38 Nm
Control valve, connector nut to cover.................................................................................................... 6 - 8 Nm
ELECTRICAL SPECIFICATIONS
Solenoid coil resistance (forward-reverse travel, high/low, 2nd/1st gear, modulation,
disconnection) ..................................................................................................................... 28 2 at 20 C
Electronic controlled modulation valve, coil resistance ...................................3.55 Ohm ( 0.25 Ohm) at 20 C
Speed sensor:
- type ................................................................................. magneto resistive sensor with 7/14 mA current loop
- frequency ......................................................................................................................................0 - 25000 Hz
- sensing distance .............................................................................................................................. 0 - 2.5 mm
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CONTROLS
4X2 POWERSHIFT TRANSMISSION CONTROL
1. POWERSHIFT TRANSMISSION GEARSHIFT

AND DIRECTION LEVER: four gears are selectable for the required ground speed in forward and two gears for reverse travel.
IMPORTANT: the gearshifts and the direction of
travel are governed by the microprocessor, which
enables smooth and safe changes, irrespective of
the selected gear. Therefore upshifting, downshifting or change of travel direction by means of the
gears will only occur when the monitored machine
speed is safe to do so.
2. DIFFERENTIAL LOCK SWITCH: depressing
the spring loaded switch will lock both rear
wheels together giving equal drive and will disengage when wheel torque equalises or the foot
brakes are applied.
3. LOADER ATTACHMENT CONTROL LEVER
4. TRANSMISSION DISCONNECT BUTTON
3
5. ROLLER FOR THE PROPORTIONAL CONTROL OF LOADER BUCKET 4x1
6. KICKDOWN SWITCH: if the machine is in 2nd
gear and 1st is required for loader work engaging kickdown instantly drops the gear from 2nd
to 1st. When reverse is selected the transmission reverts to 2nd gear.
4x2 powershift transmission
The transmission installed on this machine has
been designed for gearshifting, although it continues driving the wheels, according to the selected ratio and travel direction. The transmission is
controlled by a microprocessor located in the powershift gearshift lever unit (1).
The gearshift lever (1) with electronic gear selection
actuates the powershift gearshift with 4 forward and
2 reverse speeds.
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Powershift 4x2 (EGS) transmission display - Forward travel selection
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Powershift 4x2 (EGS) transmission display - Reverse travel selection
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Powershift lever display - (LEDs)

LEDs - Numbered 1 to 4:
Indicate the direction of travel by the colour of the
LED
Forward = Green
Neutral = Red
Reverse = Orange
and they also indicate the selected gear.
3
STEADILY ILLUMINATED LED: indicates selected
transmission gear.
FLASHING LED: indicates the actual transmission
gear engaged (if different from that selected).
LEDs - Numbered 1 to 8: used during test modes
LED - Number 8: illuminates green when the machine is at a standstill (in normal mode).
LED - Letter T = Self-diagnostic mode:
Used in self-diagnostic test mode and will illuminate

during self test.
NOTE: in the event of a fault, (the light will flash),
Contact your Authorized Dealer for assistance.
LED - Letter N indicates Neutral:
Illuminates when the transmission is shifted to neutral.

Powershift lever and microprocessor functions
The microprocessor controls the transmission and
self checks its own memory continuously to ensure
that gear selection and range changes are always
performed in a safe manner.
Should a fault occur in the transmission or the microprocessor, the microprocessor will default to the reset mode.
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Reset Mode:
When the microprocessor defaults to reset mode
both the T and N LEDs are displayed simultaneously
to indicate that a reset has taken place.
If no critical faults are active the microprocessor selects N2 and goes to the Neutral lock state. See
Driving with powershift chapter.
Limp home function:
If a fault is detected at power-up, the limp home function is automatically selected.
IMPORTANT: if limp home is active, only 1st and
2nd gear will be selectable but without modulation.
The limp home function is active when the following
LEDs are on.
- Consult your Dealer.
LED - T
LED - N
CONDITION
Flashing
ON
Last fault currently shown on display
Flashing
Slower flashing
Input error detected
Flashing
Flashing in phase
Non-critical output error detected
Flashing
Faster flashing
Safety critical output error detected
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Selecting neutral position

At power up, Neutral and 2nd Gear are automatically selected regardless of the powershift lever position (1). The LED-2 and the LED-N are illuminated
in RED (neutral, 2nd) and the microprocessor is in a
neutral lock state. If, after driving, neutral is selected
and the shift lever stays in neutral for more than 3
seconds, the microprocessor automatically defaults
to the neutral lock state for safety reasons. In neutral
position, an automatic shift routine activates to prevent damage to the transmission due to overspeed.
Neutral state
A feature of the powershift lever is the neutral lock
state, which does not allow forward or reverse direction drive to be selected. This feature prevents the
machine accidentally moving should the lever be
knocked into forward or reverse. To leave the neutral
lock state, you select drive direction followed by an
upshift by rotating the shift lever.
Selecting forward travel
To select forward travel push the lever away from
you and the F LED will illuminate green.
NOTE: when forward is selected you will not be given any indication of gear selected, only the maximum selected gear the transmission will shift too.
The microprocessor is programmed to be an automatic gearshift system. In addition, if the forward
travel is now actually engaged, according to the status of the machine (for example, if it is moving), the
microprocessor considers the road travel speed and
the travel direction before any gearshift takes place.
Selecting reverse travel
To select reverse travel pull the lever towards you
and the reverse R LED will illuminate orange.
NOTE: when reverse is selected you will not be given any indication of gear selected, only the maximum selected gear the transmission will shift too.
The microprocessor is programmed to be an automatic gearshift system.
In addition, if the reverse travel is now actually engaged, according to the status of the machine (for
example, if it is moving), the microprocessor considers the road travel speed and the travel direction.
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Upshifting
Upshifting is achieved by turning the handgrip counterclockwise (+) in single movements. If this position
is held, the processor advances the gear selection
from 2nd to 4th with intervals of 1.8 seconds.
NOTE: an upshift request after a downshift is delayed for 2 seconds. Should an error occur with the
speed sensor the microprocessor will not allow upshifts above 2nd gear and will be indicated by the T
LED flashing and the N LED flashing slower.
NOTE: if climbing up a steep incline select 2nd and
proceed, if speed and power allow upshift into 3rd
and 4th.
Downshifting
S WARNING
If descending down a steep slope, select the second
gear, upshifting only when it is safe to do so. You
cannot downshift to reduce speed if the machine
speed is above 15 km/h.
Downshifting to the desired gear is achieved by
twisting the knob clockwise (-) in single movements.
If the knob is held in this position, the processor will
downshift from the fourth (if the gearshift lever is in
this position) to the first gear in intervals of 1.5 seconds.
NOTE: if the gear requested and the shift attainable
are not the same because of torque converter turbine rpm being too high, the gear position LED (e.g.
LED 4) will flash and the shift lever position will illuminate, not flashing, (e.g. LED 2), until the requested
gear is reached. When a gear position LED is flashing this indicates that the machine has to reduce
speed to reach the requested gear.
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Direction Changes
Changing driving direction is achieved simply by
shuttling the powershift lever between forward and
reverse and vice versa which is allowed at any time.
The system response however depends on machine
speed and currently engaged gear. When driving in
1st or 2nd gear direction changes are unrestricted
and are granted immediately.
F1 - R1
F2 - R2
R1 - F1
R2 - F2
When driving forward in 3rd or 4th gear two responses are possible depending on machine speed.
RESPONSE 1: if the machine speed in forward is
above 15 km/h and reverse is selected downshift engages but momentum forward remains, until the
speed lowers sufficiently to allow downshift to take
place when reverse is achieved in 2nd gear.
RESPONSE 2: if the machine speed in forward is
less than 15 km/h reverse takes place immediately
into 2nd gear.
Should a speed sensor fault be detected while in F3
or F4 a downshift sequence to 2nd gear will take
place and is indicated by the LED T flashing fast
and the LED N flashing slowly.
NOTE: if the transmission is in 1st gear forward after
a quick downshifting, the travel direction change determines the selection of the second reverse travel in
order to guarantee an efficient response. Refer to
kickdown for more information.
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Powershift transmission
In the previous paragraphs shift changes have been
shown as precise movements and twist actions of
the powershift lever. However the transmission can
change gear automatically in forward or reverse as
described in the following paragraph:
Select the 4th forward gear with the powershift lever;
then, with the parking brake disengaged, press the
accelerator pedal. As the engine revs and machine
speed increase the transmission will start from 2nd
gear and change up through 3rd and 4th gears up to
maximum road speed. When you require to slow
down or stop release the foot accelerator and apply
the foot brake, the transmission will automatically
downshift through 4th, 3rd and 2nd gear as the machine speed decreases. Once stopped, engage the
parking brake; now the neutral position will be selected by the microprocessor. To start travelling again,
simply twist the handgrip to select the 4th gear and,
with the parking brake disengaged, press the accelerator pedal.
Kickdown
The kickdown facility (2nd to 1st gear only) on this
transmission increases torque instantly to the driving
wheels and hence pushing power. For example
when the loader is pushing into a pile and more
torque is required at the wheels. This is achieved by
the instant gearshift from 2nd to 1st by the use of the
button (1) without the need to use the twist grip on
the powershift lever.
NOTE: the kickdown function is available only when
the transmission is in 2nd gear and the appropriate
button (1) is pressed. If downshifting is impossible
(machine speed too high), the LED 1 is on and the
LED 2 flashes.
Transmission disconnection
The disconnect feature is useful when loading, for
example; when pushing the loader into a pile and you
have sufficient dirt in the bucket press the disconnect
switch (1) which disengages the transmission and allows the full power of the engine to be directed to the
hydraulic oil pump. Disconnect is available in 1st and
2nd gear.
NOTE: transmission disconnect is selectable, when
the machine speed is less than 5 km/h and by depressing the button on the loader lever and remains
active until the pedals or switch are released.
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Speed Ranges
The microprocessor controlling the powershift transmission is pre-programmed to control the speed at
which the gearshifts take place.
This effectively protects the transmission from excess forces, should gearshifts be selected at higher
speeds than is desirable.
(Except 695SR) shown in the chart opposite with an
18.4 X 26 R4 tyre fitted is the approximate (within
10%) maximum speed available and at which speed
an automatic shift takes place in each gear.
(...) = Automatic upshift speed
[...] = Automatic downshift speed
As it can be seen, when downshifting from the 4th
gear at a maximum speed of 39.5 km/h, the microprocessor will not allow the downshift to take place
until the speed has dropped to approximately 19.9
km/h.
Refer to the chart for the details regarding upshifting
and downshifting.
NOTE: in some countries the road speed of 40 km/h
is not allowed. In these circumstances the transmission is governed to a maximum of 30 km/h and the
shift speed range reduces accordingly.
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105
LUBRICATION
Oil capacity................................................ 14 litres

Suggested oil .......... Axcela Trans XHD MAT3525
Daily
Check oil level daily with engine running at idle (600
rpm) and oil at 82 - 93 C.
Maintain oil level at full mark.
Normal drain period
Normal drain period and oil filter change are for average environment and duty cycle condition.
Severe or sustained high operating temperature or
very dusty atmospheric conditions will cause accelerated deterioration and contamination.
For extreme conditions judgement must be used to
determine the required change intervals.
Z Every 1000 hours change oil filter.
Z Every 1000 hours drain and refill system as follows: drain with oil at 65 - 93C.
- Drain transmission.
- Oil filter, remove and discard, install new filter.
- Refill transmission (14 litres).
- Run engine at idle (600 rpm) to prime converter
and lines.
- When oil temperature is at 82 - 93 C adjust oil level
to full mark.
NOTE: it is recommended that oil filter be changed
after 100 hours of operation on new, rebuilt or repaired unit.
1
F27717
1. Drain plug
2. Oil level plug
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2.4
PRESSURE SPECIFICATIONS AND CHECK POINTS
Normal operating temperature 70 - 120 C measured at temperature check port to cooler.

Maximum
120 C.
allowed
transmission
Filter by-pass valve set to 4.1 - 5 bar (*).

Lube pressure (*) 0.3 - 0.5 bar at 47 l/min pump flow
(1800 rpm).
temperature
Internal leakage (*) 1.5 - 3.0 l/min for each clutch.

Maximum total leakage 6.8 l/min (clutch leakage +
range + converter leak + valve leak) without disconnect clutch.
Transmission regulator pressure (*) - (neutral 2nd

speed).
Z at 600 rpm: 16.5 bar.
Z at 2200 rpm: 19.6 - 23.1 bar.
Safety valve: cracking pressure (*) 9.5 - 10.5 bar.
Pump delivery (*):

Z at 2200 rpm in neutral 2nd speed: 64.9 l/min minimum.
Z at 2200 rpm in reverse 1st, 2nd, forward 1st, 2nd
maximum 3 l/min less than in neutral 2nd.
Z at 2200 rpm in forward 3rd and 4th: maximum 5 l/
min less than in neutral 2nd.
To cooler (converter out) pressure (*) 2 bar minimum at 2000 rpm and maximum 5 bar at no load
governed speed.
Converter by-pass valve set to 5-7 bar (*).
(*) All pressures and flows to be measured with oil
temperature of 82 - 93 C.
Clutch pressures (*) at 2200 rpm:

Z 18.1 - 21.5 bar clutch activated.
Z 0 - 0.2 bar clutch released.
A
2
3
4
5
6
7
8
1
F27718
A. Front view
B. Rear view
1. Dipstick hole M27 x 2.5
2. Pressure check port forward hi clutch (forward
3rd and forward 4th) 18.1-21.5 bar
3. Pressure check port from cooler (lube pressure)
4. Pressure check port forward port forward low
clutch (forward 1st and forward 2nd)
5. To cooler 18.1-21.5 bar

6. Pressure check port reverse clutch (reverse
1st and reverse 2nd) 18.1-21.5 bar
7. Pressure check port 1st clutch (forward 1st, forward 3rd, reverse 1st) 18.1-21.5 bar
8. From cooler
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14
13
9
11
10
12
F27719
C. Left side view

D. Top view
9. Pressure check port converter in 5-11 bar
10. Pressure check port 2nd clutch (forward 2nd forward 4th - reverse 2nd) 18.1-21.5 bar
11. To cooler
12. Pressure check port 4WD 18.9-27.5 bar
13. Pressure check port regulator pressure 19.623.7 bar
14. Filter plug M22 x 1.5
15
16
17
F27720
E. Bottom view
F. Right side view
15. Temperature check port converter out to cooler
M10 x 1
16. Pressure check port converter out to cooler

1.0625-12 UN2B SAE
17. Pressure before filter
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2.5
TRANSMISSION COOLER
F27721
1. To cooler from converter

2. Transmission cooler
3. From cooler to transmission lube distributor
COOLING SYSTEM SPECIFICATIONS
Suitable for operation from ambient to 120 C continuous operating temperature.
Must withstand a 20 bar continuous pressure and a
40 bar variable pressure.
Confirm SAE J1019 and SAE J517, 100RI.
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HYDRAULIC DIAGRAM
1
2
34
bar
33
bar
AA
C
32
bar
71
C
9
8
23
10
24
25
26
27
28
17
31
bar
12
11
35
bar
20
19
18
46
bar
45
bar
44
bar
42
bar
41
bar
47
bar
13
14
15
16
21
29
30
31
32
33
34
22
F27722
X
bar
Pressure check port
X
C
Temperature check port
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
Pressure gauge
Thermometer
Torque converter
Torque converter (pressure difference 4 bar) bypass valve
Radiator
Lubrication
Safety valve 10 bar cracking pressure
Solenoid pressure 5 bar
Pressure regulator valve 20 bar
By-pass valve pressure difference 4.3 bar
Filter
Pump
Air breather
Filter
Oil sump
Pressure reducer to 5.5 bar
18. Accumulator
19. Pressure booster 0 - 5.5 to 0 - 20 bar
20. Electronic controlled modulation valve 5.5 to
0 bar
21. Modulated pressure 0 to 20 bar
22. Clutch pressure 20 bar
23. Solenoid N/forward
24. Solenoid N/reverse
25. High/low solenoid
26. Solenoid 2nd/1st
27. Solenoid range modulation
28. Solenoid disconnect
29. Reverse clutch
30. Forward low clutch
31. Forward high clutch
32. 2nd clutch
33. 1st clutch
34. Disconnect clutch
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2.7
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OPERATION
The transmission and hydraulic torque converter of the power train enacts an important role in transmitting engine power to the driving wheels. In order to properly maintain and service these units it is important to first
understand their function and how they operate.
The transmission and torque converter function together and operate through a common hydraulic system.
With the engine running, the transmission charging pump draws oil through the oil suction filter and directs it
through the oil filter and pressure regulating valve.
Across the oil filter is a filter by-pass valve which will open if the pressure difference becomes higher than
4.3 bar.
The pressure regulating valve maintains pressure for the control valve and clutches at 20 bar.
Excess oil volume is bled off into the converter system. A safety valve is fitted between the pressure regulator
and converter.
The valve will open if pressure in this system becomes higher than 10 bar.
After entering the converter the oil is directed through the converter blade cavity and exits in the passage between the turbine shaft and pump drive shaft. Flows to the cooler.
After leaving the cooler the oil is directed to a fitting on the transmission.
Then through a series of tubes and passages lubricates and cools the transmission bearings and clutches.
The oil then gravity drains back to the transmission sump.
Across the converter and oil cooler is a converter by-pass valve which will open if the pressure difference is
higher than 4 bar (during start up from cold or at high rpm).
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Basically the transmission is composed of five main assemblies:
F27723
The converter and pump drive section

The input or directional clutches
The range clutches
The output section
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THE CONVERTER AND PUMP DRIVE SECTION

Engine power is transmitted from the engine flywheel to the impeller through the impeller cover.
This element is the pump portion of the torque converter and is the primary component which starts the
oil flowing to the other components which results in
torque multiplication. This element can be compared
to a centrifugal pump in that it picks up fluid at its
centre discharges at its outer diameter.
The torque converter turbine is mounted and discharge opposite the impeller and is connected to the
turbine shaft or directional clutch shaft.
This element receives fluid at its outer diameter and
discharges at its centre.
The stator of the torque converter is located between and at the centre of the inner diameters of the
impeller and turbine elements. Its function is to take
the fluid which is exhausting from the inner portion of
the turbine and change its direction to allow correct
entry for recirculation into the impeller element.
This recirculation causes the converter to multiply
torque.
The converter will multiply engine torque to its designed maximum multiplication ratio when the turbine shaft is at zero RPM (stall).
Therefore we can say that as the turbine shaft is decreasing in speed, the torque multiplication is increasing.
In the impeller cover a splined shaft is fitted which
runs inside and through the turbine shaft to drive a
hydraulic pump which is fitted at the back of the
transmission.
Since the shaft is connected to the centre of the impeller cover, the pump speed will be the same as engine speed.
The rear side of the impeller cover has a tanged drive
which drives the transmission charging pump located in the converter housing. The transmission charging pump speed is also the same as the engine
speed.
F27724
The converter and pump drive section
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THE INPUT OR DIRECTIONAL CLUTCHES

The turbine shaft driven from the turbine transmits
power to the forward or reverse clutches.
These clutches consists of a drum with splines and
a bore to receive a hydraulic actuated piston.
The piston is oil tight by the use of sealing rings.
A steel disc with external splines is inserted into the
drum and rests against the piston.
Next, a friction disc with splines at the inner diameter
is inserted.
Discs are alternated until the required total is
achieved.
A back up plate is then inserted and secured with a
snap ring.
A hub with outer diameter splines is inserted into the
splines of discs with teeth on the inner diameter.
The discs and hub are free to increase in speed or
rotate in the opposite direction as long as no pressure is present in that specific clutch.
To engage the clutch, the control valve which is fitted
on the side of the transmission will direct oil under
pressure through tubes and passages to the selected clutch shafts.
Oil seals are located on the clutch shafts.
These rings direct the oil through a drilled passage
in the shaft to the desired clutch.
Pressure of the oil forces the piston and discs
against the back up plate.
The discs with splines on the outer diameter clamping against discs with teeth on the inner diameter enables the drum and hub to be locked together and
allows them to drive as one unit.
When the clutch is released, a return spring will push
the piston back and oil will drain back via the control
valve into the transmission sump.
The T16000 transmission has one reverse clutch
and two forward clutches (forward low and forward
high).
This in combination with the two range clutches result in the transmission having 4 forward speeds and
2 reverse speeds.
The engagement of the directional clutches is modulated; which means that clutch pressure is built up
gradually.
This will enable the unit to make forward, reverse
shifts while the vehicle is still moving and will allow
smooth engagement of drive.
The modulation is controlled electronically in the
control valve.
F27725
The input or directional clutches
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THE RANGE CLUTCHES

Once a directional clutch is engaged power is transmitted to the range clutches (1st or 2nd).
Operation and actuation of the range clutches is
similar as the directional clutches.
The engagement of the range clutches is also modulated to enable a smooth engagement.
The modulation of these clutches is achieved by
means of a restrictor valve fitted in the control valve
and controlled electronically. It also limits the oil flow
to the clutch during shifts.
In the clutch itself the plate before the end plates is
dished to build up the clamping force of the clutch
gradually.
F27726
The range clutches

THE OUTPUT SECTION
With a range clutch engaged power is finally transmitted to the output shafts.
The transmission can have an upper output or lower
output at the rear side of the unit, and a lower output
at the front side. The rotation of the rear upper output
is opposite to the engine rotation when forward travel is selected. The rotation of the rear lower output
and of the front output is the same as the engine rotation when forward travel is selected.
Ratio between upper and lower output is 0.951:1.
The lower front output has an axle disconnect clutch
to enable 4WD.
The clutch is similar as the other clutches except that
it has no modulation.
The disconnect is controlled electronically. Without
an electrical signal the clutch is always engaged.
F27727
The output section
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THE TRANSMISSION CONTROLS

The transmission is controlled by an electronic gear
selector (EGS). This unit has a microprocessor
which receives certain inputs (gear selector position,
speed sensor...) which are processed and will give
output signals to the control valve.
The valve assembly has: 6 solenoid, 6 shift spools,
a pressure reducer, an electronic controlled modulation valve, an accumulator, a pressure booster and
a speed sensor.
Operation of the valve is as follows:
Regulated pressure 20 bar is directed to the shift
spools, pressure booster and pressure reducer.
In the pressure reducer, regulated pressure is reduced to 5.5 bar. This reduced pressure is used as
supply for the solenoid and electronic controlled
modulation valve.
When activated, the electronic controlled modulation
valve will give an output pressure curve from 0 to 5
bar.
This pressure curve is multiplied in the pressure
boost valve. In this way, for the directional clutches
a curve of 0-20 bar is available.
Between the electronic modulation valve and the
booster is an accumulator to damper any hydraulic
vibration.
When forward is selected the electronic modulation
valve and the forward solenoid are activated.
The pilot pressure of the forward solenoid will move
the shift spool so that a forward clutch can be fed
with modulated pressure.
If the high/low solenoid is not activated the forward
high clutch is engaged, if it is activated the forward
low clutch is engaged.
When reverse is selected the electronic modulation
valve and the reverse solenoid are activated, the pilot pressure of the reverse solenoid will move the
shift spool so that the reverse clutch can be fed with
modulated pressure.
The shift spools from forward and reverse are located against each other with a return spring in between; this is to make sure that only one direction
can be selected.
Range is selected as follows:
if the range solenoid (2nd/1st) is not activated, regulated pressure is fed through the modulation shift
spool and through the 2nd/1st shift spool to the 2nd
clutch.
If the range solenoid (2nd/1st) is activated, the pilot
pressure will move the shift spool so that 1st clutch
is fed.
F27728
The transmission controls
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The range clutches also have modulation which operates as follows:

When the range is changed, oil will flow through the
modulation shift spool to the chosen range clutch
momentary until the friction discs are closed against
the dished plate. At that moment the range modulation solenoid is activated. The pilot pressure will
move the modulation shift spool so that oil supply is
fed through a restrictor which is in by-pass of the
valve. The controlled volume of oil is used to push in
the dished outer plate gradually until the clutch is fully closed.
This will give a smooth build up of torque. At that moment the range modulation solenoid is released, so
that the modulation shift spool return to its rest position and allowing full oil flow to the clutch. The control
valve also controls the front lower output disconnect
clutch. If the solenoid is not activated full oil pressure
is fed through the disconnect shift spool to the disconnect clutch. If the solenoid is activated, pilot pressure will move the disconnect shift spool to block oil
supply to the disconnect clutch to release it. The control valve also has a speed sensor. This sensor will
pick up upper output gear speed.
This information is used in the electronic gear selector to determine shift logic.
Since the sensor picks up upper output gear speed,
the signal will be in direct relation of the turbine
speed if any directional clutch is engaged.
Transmission gear
Activated solenoids
Activated clutches
Forward 4
Forward
Forward high, 2nd
Forward 3
Forward, 2nd/1st
Forward high, 1st
Forward 2
Forward, forward high/low
Forward low, 2nd
Forward 1
Forward, forward high/low, 2nd/1st
Forward low, 1st
Reverse 1
Reverse, 2nd/1st
Reverse, 1st
Reverse 2
Reverse
Reverse, 2nd
Disconnect off
Disconnect
---------------
Disconnect on
---------------
Disconnect
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2.8
117
POWER FLOWS
F27730
F27729
1st speed forward
2nd speed forward
F27731
3rd speed forward
F27132
4th speed forward
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F27734
F27733
1st speed reverse
2nd speed reverse
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OPERATING VALVES AND SOLENOIDS
F29986
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Transmission sump
Transmission breather
Suction strainer
Gerotor oil pump
Pressure oil filter
Filter by-pass valve 4.3 bar
System pressure regulating valve 20 bar
Oil to converter system
Neutral reverse shift spool
Pressure booster 0-20 bar
Neutral forward solenoid
High/low shift spool
High/low solenoid
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Neutral reverse solenoid

1st gear clutch
Accumulator
Electronic modulation valve 0-5.5 bar
Pressure reducing valve 5.5 bar
2nd/1st shift spool
Range modulation spool
Range modulation restriction
4WD shift spool
4WD solenoid
Range modulation solenoid
2nd/1st Solenoid
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TORQUE CONVERTER AND COOLER SYSTEM
F29987
Suction oil
Return to oil tank
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Transmission sump
Suction strainer
Gerotor oil pump
Pressure oil filter
System pressure test port 20 bar
Oil flow to control valve
Torque converter system relief valve 10 bar
Converter system pressure test port 5 bar
Torque converter
Converter oil temperature port
Oil cooler pressure test port
Converter pressure by-pass valve 4 bar
Oil cooler
Aftercooler oil temperature port
Lubrication pressure port
Lubrication galleries
High pressure oil

Torque Converter and Lubrication Oil
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SERVO CONTROL PRESSURE SYSTEM
F29988
Suction oil
High pressure oil
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Transmission sump
Suction strainer
Gerotor oil pump
Pressure oil filter
Oil flow to converter
Oil flow to shift spools
Return to oil tank

Pilot pressure
Modulated pilot oil
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
2nd/1st Solenoid
4WD solenoid
High/low solenoid
Accumulator
Modulated pressure to shift spools 0-20 bar
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SERVO CONTROL FORWARD SECOND GEAR 4WD ENGAGED

System pressure is reduced to 5.5 bar by the pressure reducer this oil then supplies the 6 solenoids and electronic modulation valve.
When the powershift lever is moved forward and twisted anti clockwise an electrical signal is sent to:
Z The high low solenoid which energizes allowing pilot oil to flow to the shift spool.
Z The neutral forward solenoid which energizes allowing pilot oil to flow to the shift spool.
Z The powershift lever will then reduce the current to the modulation valve which gives an output pressure curve
from 0 to 5.5 bar to the pressure booster valve.
Z The modulation pressure curve is multiplied by 4 in the pressure booster so that a curve of 0-20 bar is available for the directional clutches.
Between the modulation valve and the booster is accumulator to dampen any hydraulic vibration.
F29989
Suction oil
High pressure oil
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Transmission sump
Suction strainer
Gerotor oil pump
Pressure oil filter 20 bar
Oil flow to shift spools 0-20 bar
Return to oil tank

Pilot pressure
Modulated pilot oil
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
2nd/1st Solenoid
4WD solenoid
High/low solenoid
Accumulator
Modulated pressure to shift spools
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SERVO CONTROL FORWARD THIRD GEAR 4WD ENGAGED

Z When the powershift lever is moved forward and twisted anti clockwise an electrical signal is sent to:
Z The range modulation solenoid sending pilot pressure to the spool.
Z The 1st 2nd solenoid sending pilot pressure to the spool.
Z Once the 3rd gear has been engaged the range modulation solenoid will be de-energized.
Z The high/low solenoid prevents pilot oil to flow to the shift spool.
Z The neutral forward solenoid allowing pilot oil to flow to the shift spool.
Z The powershift electronics will then reduce the current to the modulation valve which gives an output pressure
curve from 0-5.5 bar to the pressure booster valve.
Z The modulation pressure curve is multiplied by 4 in the pressure booster so that a curve of 0-20 bar is available for the directional clutch.
Z The 4WD solenoid supplies pilot oil to the shift spool.
F29990
Suction oil
High pressure oil
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Transmission sump
Suction strainer
Gerotor oil pump
Pressure oil filter
Return to oil tank

Pilot pressure
Modulated pilot oil
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
2nd/1st Solenoid
4WD solenoid
High/low solenoid
Accumulator
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SERVO CONTROL REVERSE FIRST GEAR 4WD ENGAGED

When the powershift lever is moved rearward and twisted clock wise a electrical signal is sent to:
Z The range modulation solenoid sending pilot pressure to the spool.
Z The 1st 2nd solenoid sending pilot pressure to the spool.
Z Once the 1st gear has been engaged the range modulation solenoid will be de-energized.
Z The low/high solenoid sends pilot oil to the shift spool.
Z The neutral reverse solenoid allowing pilot oil to flow to the shift spool.
Z The powershift lever microprocessor will then reduce the current to the modulation valve which gives an output pressure curve from 0-5.5 bar to the pressure booster valve.
Z The modulation pressure curve is multiplied by 4 in the pressure booster so that a curve of 0-20 bar is available for the directional clutches.
F29991
Suction oil
High pressure oil
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Transmission sump
Suction strainer
Gerotor oil pump
Pressure oil filter
Return to oil tank

Pilot pressure
Modulated pilot oil
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
2nd/1st Solenoid
4WD solenoid
High/low solenoid
Accumulator
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CONTROL VALVE OPERATION FORWARD, SECOND GEAR WITH 4WD ENGAGED

Pressure oil from the system regulating valve flows to the pressure reducing valve.
The pressure lowers to 5.5 bar. This oil flows to the 6 solenoids.
Oil also supplies the modulation valve.
When the powershift lever is moved forward and twisted anti clock wise a electrical signal is sent to:
Z Oil flows from the system pressure regulating valve at 20 bar through the 4WD spool to engage the 4WD
clutch.
Z System pressure also flows through the range modulation valve, then through the 1st 2nd spool to engage
the 2nd gear clutch.
Z The high low solenoid which energizes allowing pilot oil to flow to the shift spool. This will allow oil to flow to
the low clutch.
Z The neutral forward solenoid which energizes allows pilot pressure to flow to the shift spool this will allow oil
to flow on to the forward low shift spool.
Z The modulation valve has a reducing current from the microprocessor, pilot pressure gradually increases acting on the boost valve and it multiplies pilot pressure.
Z The oil from the boost valve is modulated allowing a steady increase of pressure to act on the forward low
clutch pack which gradually takes up drive until clutch pressure reaches 20 bar.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Transmission sump
Suction strainer
Gerotor oil pump
Pressure oil filter
2nd/1st Solenoid
2nd/1st shift spool
2nd gear clutch
1st gear clutch
4WD solenoid
4WD shift spool
4WD clutch
High/low solenoid
Forward high clutch
Forward low clutch
Reverse clutch
Neutral forward shift spool
Accumulator
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F29992
Suction oil
High pressure oil
Return to oil tank

Pilot pressure
Modulated pilot oil
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CONTROL VALVE OPERATION FORWARD, THIRD GEAR WITH 4WD DISENGAGED

Pressure oil from the system regulating valve flows to the pressure reducing valve.
The pressure lowers to 5.5 bar. This oil flows to the 6 solenoids. Oil also supplies the modulation valve.
When the powershift lever is moved forward and twisted anti clock wise and the 4WD is switched off a electrical
signal is sent to:
Z The 4WD solenoid supplies pilot oil to the shift spool.
This will move the spool preventing oil flowing to the clutch disengaging 4WD.
Z The range modulation solenoid allowing pilot oil to the range modulation valve, which restricting oil flow to the
1st 2nd shift spool.
Z The 1st 2nd solenoid, sending pilot pressure to the 1st 2nd shift spool which directs oil to the 1st clutch.
Z Once the 1st gear clutch is engaged the range solenoid is de-energized and full flow will go to the 1st gear
clutch.
Z The neutral forward solenoid which energizes allows pilot pressure to flow to the shift spool this will allow oil
to flow on to the forward high shift spool.
Z The modulation valve has a reducing current from the microprocessor, pilot pressure gradually increases acting on the boost valve and it multiplies pilot pressure by 4.
The oil from the boost valve is modulated allowing a steady increase of pressure to act on the forward high
clutch pack which gradually takes up drive until clutch pressure reaches 20 bar.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Transmission sump
Suction strainer
Gerotor oil pump
Pressure oil filter
System pressure test port
2nd/1st Solenoid
2nd/1st shift spool
2nd gear clutch
1st gear clutch
4WD solenoid
4WD shift spool
4WD clutch
High/low solenoid
Forward high clutch
Forward low clutch
Reverse clutch
Accumulator
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F29993
Suction oil
High pressure oil
Return to oil tank

Pilot pressure
Modulated pilot oil
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CONTROL VALVE OPERATION REVERSE, FIRST GEAR WITH 4WD ENGAGED

Pressure oil from the system regulating valve flows to the pressure reducing valve. The pressure lowers to 5.5
bar. This oil flows to the 6 solenoids.
Oil also supplies the modulation valve. When the powershift lever is moved rearwards, the kickdown button is
pressed and the 4WD is switched off, an electrical signal is sent to:
Z The range modulation solenoid allowing pilot oil to the range modulation valve, which restricting oil flow to the
1st 2nd shift spool.
Z The 1st 2nd solenoid, sending pilot pressure to the 1st 2nd shift spool which directs oil to the 1st clutch.
Z Once the 1st gear clutch is engaged the range solenoid is de-energized and full flow will go to the 1st gear
clutch.
Z The neutral reverse solenoid which energizes allows pilot pressure to flow to the shift spool. This will allow oil
to flow on to the reverse shift spool.
Z The modulation valve has a reducing current from the microprocessor, pilot pressure gradually increases acting on the boost valve and it multiplies pilot pressure.
Z The oil from the boost valve is modulated allowing a steady increase of pressure to act on the reverse clutch
pack which gradually takes up drive until clutch pressure reaches 20 bar.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
Transmission sump
Suction strainer
Gerotor oil pump
Pressure oil filter
2nd/1st Solenoid
2nd/1st shift spool
2nd gear clutch
1st gear clutch
4WD solenoid
4WD shift spool
4WD clutch
High/low solenoid
Forward high clutch
Forward low clutch
Reverse clutch
Accumulator
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F29994
Suction oil
High pressure oil
Return to oil tank

Pilot pressure
Modulated pilot oil
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PRESSURE TESTING TORQUE CONVERTER AND COOLER CIRCUIT

All pressure and flow testing should be measured with an oil temperature of 82 - 93 C.
For operating speed refer to each test.
Port 1 System pressure.
Z Engine set to 750 rpm minimum pressure 15 bar.
Z Engine set to 2200 rpm 19.6-23.1 bar.
Port 2 Torque converter in.
Z Engine set to 2200 rpm oil pressure range 5-11 bar.
Port 3 Torque converter out.
Z Engine speed 2000 rpm minimum pressure 2 bar.
Z Engine speed 2200 rpm maximum pressure 5 bar.
Port 4 Oil temperature converter out.
Z Normal operating temperature 80-90 C.
Maximum temperature 120 C.
Port 5 Oil temperature cooler out.
Z T.B.A.
Port 6 Lubrication pressure.
Z Engine speed 2000 rpm pressure range 0.8-2.0 bar.
HYDRAULIC OIL FLOWS
Oil flows to the pressure regulating valve, maintaining system pressure to the control valve and clutches at 20
bar.
Excess oil flow is bled to the converter system which is protected by a 10 bar safety valve.
Oil enters the converter through the converter blade cavity and exits in the passage between the turbine shaft
and pump drive.
Oil then flow to the external cooler.
Across the converter and the oil cooler system a by-pass valve is fitted; if the pressure difference is more than
4 bar, the valve will open. Excess oil is directed to the lubrication system.
This protects the system during start up from cold oil or at high rpm.
After leaving the cooler the oil is directed via a single fitting on the rear of the transmission to a series of tubes
and passages, to lubricate and cool the transmission bearings and clutches.
Oil is drawn up from the sump, via an internal strainer, through the inlet port of the hydraulic pump.
Oil is pumped out to the pressure filter.
Across the oil filter is a filter by-pass valve which will open if the pressure difference becomes higher than
4.3 bar.
The oil then gravity drains back to the transmission sump.
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2.9
GEAR AND CLUTCH LAY OUT
t
Ou
In
Ou
F27735
Forward low
Forward high
Reverse and 1st
2nd
Disconnect
Input shaft
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2.10 TRANSMISSION REMOVAL AND INSTALLATION

REMOVAL
S WARNING
Before performing any service or maintenance on the machine ensure the wheels are chocked/blocked to prevent the machine from moving.
1. Lower the loader to the ground or raise and secure (dependent upon lifting apparatus) and release any
pressure in the system as required. Engage the parking brake and block the wheels.
2. Stop the engine.
3. Isolate battery.
4. Remove all engine panels.
5. Remove front cast cowling.
6. Drain engine coolant and remove hoses.
IMPORTANT: air conditioning where fitted - Do not disconnect the air conditioning hoses from the compressor
or condenser unless a refrigerant reclaim system is to be used. Engine/Transmission removal from the machine does not require the system to be discharged.
Remove the condenser from the front radiator and place the condenser to one side of the chassis.
Disconnect the air conditioning compressor attaching hardware and place the compressor to one side of the
chassis.
Disconnect the expansion bottle connections from the radiator.
7. Remove all attaching bolts from radiator.
8. Disconnect transmission cooler pipes.
9. Remove radiator, taking care not to damage the fan or hydraulic oil cooler.
10. Remove the air filter assembly.
11. Disconnect all electrical connections.
12. Disconnect hydraulic pipe clamps.
13. Disconnect the fuel tank feed and return pipes.
14. Disconnect the foot throttle cable at the fuel injection pump.
15. Remove the cab mat.
16. Remove the cab floor access panel.
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17. Disconnect the 12 pin connector from the transmission valve chest mounted to the left hand
side of the of the transmission.
18. Disconnect the transmission to lock out valve
pipe.
19. Disconnect lock out return pipe and plug the hole
(oil will leak out of transmission).
F27736
20. Remove front drive shaft (where fitted) and remove rear drive shaft.
21. Disconnect the parking brake cable.
22. Disconnect and pull back hydraulic pump (leaving all pipes attached). Check that the oil pump
drive shaft does not slide out with the pump.
23. Check return from steering motor is on the outside of transmission oil level tube.
F27737
24. With the engine supported and using a hoist

capable of supporting a total weight of 800 kg
loosen and remove the engine and transmission
mounting bolts.
IMPORTANT: if the hydraulic oil pump is removed
from the transmission / engine assembly the balance of the assembly when hoisted will be front end
heavy.
25. Using the lifting tool for the engine-transmission
assy (1) 380300030, raise and extract the engine/transmission assy from the vehicle.
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SEPARATING ENGINE FROM TRANSMISSION

1. Place the engine/transmission assembly on a
suitable splitting stand.
2. Remove the starter motor assembly.
F27739
3. Unscrew and remove the torque converter attaching bolts accessed through the starter motor
aperture (1).
4. Remove the engine timing tab (2).
5. Unscrew and remove the bell housing bolts.
6. Gently slide the transmission with the torque
converter from the engine.
2
F27740
INSTALLATION
Place a stud in one tang of the flexi plate and as the
transmission is assembled up to the engine guide
the stud through a bolt hole of the flywheel, remove
the stud and refit a bolt.
Refit the attaching bolts which couple the transmission to engine.
Turn the engine crankshaft using a torque bar to expose in turn each attaching bolt hole of the flywheel
through the flexi plate and refit all of the bolts.
Hoist the engine/transmission assembly back into
the vehicle and centralize in the machine using a
measure between the chassis and centre line of the
crankshaft pulley. This ensures the engine is centrally positioned before torque up of the engine/
transmission to chassis bolts.
Reconnect all ancillary equipment as previously described.
Ensure all attaching hardware is tightened to the
correct torque value as detailed in the specifications.
Ensure after installation that all fluid levels are correct prior to start up.
Start and run the engine until correct operating temperature is achieved to purge air from cooling system.
Stop engine, check for leaks, rectify as required and
recheck fluid levels.
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TRANSMISSION TO ENGINE INSTALLATION PROCEDURE

Remove all burrs from flywheel (1) mounting face
and nose pilot bore (3). Clean drive plate surface
with solvent.
Check engine flywheel (4) and housing (1).
Measure and record engine crankshaft end play.
Install two 63.5 mm long transmission to flywheel
housing guide studs in the engine flywheel housing
as shown. Rotate the engine flywheel to align a drive
plate mounting screw hole with the flywheel housing
access hole (3).
Install a 101.60 mm long drive plate locating stud
fine thread in a drive plate nut. Align the locating stud
in the drive plate with the flywheel drive plate (5)
mounting screw hole.
(Does not apply to units having 3 intermediate drive
plates).
Rotate the transmission torque converter to align the
locating stud in the drive plate with the flywheel drive
plate mounting screw hole (3). Locate transmission
on flywheel housing (1).
Aligning drive plate to flywheel and transmission to
flywheel housing guide studs, install transmission to
flywheel housing screws. Tighten screws to specified torque. Remove transmission to engine guide
studs. Install remaining screws and tighten to specified torque.
1
A
2
5
F27742
Remove drive plate locating stud.

Install drive plate attaching screw and washer.
Snug screw but do not tighten. Some engine flywheel housings have a hole located on the flywheel
housing circumference in line with the drive plate
screw access hole. A screwdriver or pry bar used to
hold the drive plate against the flywheel will facilitate
installation of the drive plate screws. Rotate the engine flywheel and install the remaining seven flywheel to drive plate attaching screws. Snug screws
but do not tighten.
After all eight screws are installed torque one torque
35 - 39 Nm. This will require tightening each screw
and rotating the engine flywheel until the full amount
of eight screws have been tightened to specified
torque. Measure engine crankshaft end play after
transmission has been completely installed on engine flywheel.
This value must be lower than 0.025 mm.
6. Special stud, washer and self locknut furnished
by engine manufacturer
7. Impeller cover
8. Intermediate drive plate
7
8
F27743
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2.11 TRANSMISSION COMPONENTS

CONVERTER HOUSING AND TRANSMISSION
137
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138
ITEM
DESCRIPTION
QUANTITY
Plug
11
O-ring
11
O-ring
Plug
Ball
Spring
Plug
O-ring
Spring safety valve
10
Ball
11
O-ring
12
Plug
13
O-ring converter housing to transmission case
14
O-ring converter housing to transmission case
15
Gasket converter housing to transmission case
16
Housing converter
17
Lock washer - converter housing to transmission case screw
14
18
Screw - converter housing to transmission case
14
19
O-ring filter adaptor
20
O-ring filter adaptor
21
Filter - adaptor
22
Lock washer - filter adaptor screw
23
Screw - filter adaptor
24
Assembly - filter
25
Oil seal - output shaft front
26
27
28
29
30
Clip - suction tube
31
Lock washer - suction tube screw
32
Screw - suction tube
33
O-ring suction tube
34
Retainer - suction tube
35
Assembly - tube and filter
36
Oil seal
37
Lock washer - oil baffle mounting screw
38
Screw - oil baffle mounting
39
Nut - oil baffle mounting screw
40
Lock washer - oil baffle mounting screw
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ITEM
DESCRIPTION
139
QUANTITY
41
Oil seal
42
Screw - oil baffle mounting
43
Plate - oil baffle
44
Plate - oil baffle
45
Pin - transmission case to converter dowel
46
47
48
Case - transmission
49
O-ring
50
Plug
51
Plug
11
52
O-ring
11
53
Seal upper output
54
55
56
Plug - magnetic drain
57
Snap ring - output shaft rear bearing
58
Plug - output shaft bore
59
Sealing ring - plug
60
Plug
61
Plug
62
Plug
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INPUT SHAFT, TORQUE CONVERTER, PUMP DRIVE, INTERNAL CHARGING PUMP AND DRIVE PLATE
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ITEM
DESCRIPTION
141
QUANTITY
Screw - drive plate mounting
Lock washer - drive plate mounting screw
Ring - drive plate
Plate - drive
Assembly - drive plate
Bushing - converter pilot
Assembly - torque converter
Oil seal - charging pump
Screw - pump mounting
10
Seal washer - pump mounting screw
11
Assembly - charging pump
12
O-ring charging pump
13
Ring - piston
14
Bearing - input shaft front
15
Snap ring
16
Snap ring
17
Gear - forward low and reverse drive
18
Snap ring
19
Input shaft
20
Snap ring
21
Gear - forward high drive
22
Bearing - input shaft rear
23
Ring - piston
24
Assembly - pump drive shaft and sleeve
25
Ring - piston
26
Bearing - pump drive shaft
27
Snap ring
28
Retaining ring
29
Gasket - permanent pump adapter cover
30
Cover - permanent pump adapter
31
Lock washer - permanent pump adapter cover screw
32
Screw - permanent pump adapter cover
FORWARD LOW AND FORWARD HIGH SHAFT
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17
5
3
18
1
16
11
9
12
13
14
15
10
32
31
30
29
28
27
26
25
50
24
22
23
46
21
19
20
42
40
43
44
47
48
49
45
41
39
38
33
34
35
36
37
F27746
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ITEM
DESCRIPTION
143
QUANTITY
High/low forward travel shaft bearing
Gear - forward driven
Snap ring
Bearing - clutch gear
Retaining ring - clutch gear bearing
Gear forward low clutch
Ring - clutch gear piston
10
Snap ring
11
Snap ring
12
Washer
13
Snap ring - backing plate
14
Plate - clutch disc backing
15
Disc - outer half
16
Disc - outer
17
Disc - inner
18
Disc - outer half
19
Retaining ring
20
Retainer spring
21
Spring - piston return
22
Plate spring - clutch piston wear
23
Assembly - clutch piston and seals
24
Seal - clutch piston - outer
25
Seal - clutch piston - inner
26
Assembly forward low/forward high, shaft drum and plug
27
28
29
30
31
32
Retainer spring
33
Spacer clutch spring forward high
34
Retaining ring
35
Disc - outer half
36
Disc - inner
37
Disc - outer
38
Disc - outer half
39
40
Spacer - clutch disc backing plate forward/high
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ITEM
DESCRIPTION
QUANTITY
41
Snap ring spacer
42
Thrust washer
43
Thrust bearing
44
Bearing - needle
45
Gear - forward high clutch
46
Bearing - needle
47
Thrust bearing
48
Thrust washer
49
Bearing - rear forward low/forward high shaft
50
Ring - piston
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REVERSE / 1ST SHAFT AND GEARS
9
8
7
6
4
2
3
16 17
12
13
14
18
15
32
11
31
10
30
29
27
28
26
47
25
45
24
22
44
23
43
21
19
46
42
20
41
40
36
33
37 38
39
34 35
F27747
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ITEM
DESCRIPTION
QUANTITY
Bearing - front reverse: 1st shaft
Gear - reverse driven
Snap ring
Gear forward low clutch
Ring - clutch gear piston
10
Snap ring
11
Snap ring
12
Washer
13
Snap ring - backing plate
14
15
Disc - outer half
16
Disc - outer
17
Disc - inner
18
Disc - outer half
19
Retaining ring
20
Retainer spring
21
22
23
24
25
26
Assembly reverse / 1st, shaft drum and plug
27
28
29
30
Plate clutch piston wear
31
Assembly - spring disc
32
Retaining ring
33
Disc - outer half
34
Disc - inner
35
Disc - outer
36
Disc - outer half
37
Modulation spring
38
39
Snap ring - clutch disc backing plate
40
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ITEM
DESCRIPTION
147
QUANTITY
41
42
Gear - 1st clutch
43
44
45
Snap ring
46
Bearing - rear reverse / 1st shaft
47
Ring - piston
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2ND SHAFT
7
6
5
4
3
13
10
11
14
15
12
23
22
21
19
20
31
30
18
29
17
28
16
27
26
25
24
F27748
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ITEM
DESCRIPTION
149
QUANTITY
Ring - piston
Bearing - front 2nd shaft
Washer - bearing support
Gear - 2nd clutch
10
11
Modulation spring
12
Disc - outer half
13
Disc - outer
14
Disc - inner
15
Disc - outer half
16
Retaining ring
17
Retainer spring
18
Spring clutch - piston return
19
20
21
22
23
Assembly - 2nd shaft, drum and plug
24
Snap ring - gear retainer
25
Gear - lower output drive
26
Gear - upper output
27
Bearing rear - 2nd shaft
28
Flange yoke 1410 - upper output
29
O-ring - flange
30
Washer - flange nut
31
Nut - flange
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OUTPUT SHAFT WITH INTERNAL DISCONNECT

13
12
11
10
9
8
7
6
5
22
1
21
20
19
18
16
15
17
32
31
30
29
28
14
26
27
25
24
23
F27749
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ITEM
DESCRIPTION
151
QUANTITY
Nut - flange
Washer - flange nut
O-ring - flange
Output flange front yoke 1410 with brake pads
Bearing - output shaft front
Retaining ring
Disconnect hub
Assembly - output shaft front
10
Bushing
11
12
Spacer
13
14
Disc - outer half
15
Disc - outer
11
16
Disc - inner
12
17
Disc - outer half
18
Retaining ring
19
Retainer spring
20
21
22
23
24
25
Assembly - output shaft rear, drum and plug
26
27
Gear lower output
28
29
Snap ring - rear bearing
30
Bearing - output shaft rear
31
Snap ring - rear bearing
32
Ring - piston
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PARKING BRAKE
19
20
19
18
2
1
17
15
14
21
16
13
12
11
10
F27750
ITEM
DESCRIPTION
QUANTITY
Screw - brake mounting
Assembly - caliper
Nut - brake mounting screw
Nut - jam adjustment
Nut - adjustment
Washer - hardened
Washer - stainless steel
Thrust washer
Lever
10
Boot
11
Cam
12
Oil seal
13
Ball bearing
14
Plastic retainer
15
Cam
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ITEM
DESCRIPTION
153
QUANTITY
16
Torque plate - front
17
Pads assembly
18
Torque plate - rear
19
Sleeve mounting
20
Adjuster screw
21
Spring
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ELECTRICAL CONTROL VALVE

1
2
3
ITEM
F27751
DESCRIPTION
QUANTITY
Control valve assembly
Control valve mounting screws
17
Control valve protection cover gasket
Control valve protection cover
Protection cover screw
20
Air breather
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2.12 DISASSEMBLY AND ASSEMBLY

ASSEMBLY INSTRUCTIONS
10
14
15
2
5
9
10
13
15
2
10
2
10
6
11
16
2
12
15
11
3
8
F27752
1. Add some grease to O-ring before assembly.
2. Add some grease to piston rings before assembly slots of the piston rings are not allowed to
pass bores in housings.
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3. Teflon seals must be sized prior to assembly.

Grease the inner and outer diameter of the
clutch drum before assembly.
4. Pump must be filled up with test oil prior to assembly.
5. Pump drive shaft must be installed after torque
converter.
6. Forward low, reverse, 1st, and 2nd clutch: 9
separator plates with inner splines. 8 friction
plates (friction material both sides) with outer
splines, 2 1-side friction plates (friction material
1 side) with outer splines.
Start with one 1-side friction plate, metal against
piston, then alternately separator and friction
plate.
End with a 1-side friction plate, metal side
against end plate or disc spring.
Be sure disc spring is mounted as shown.
Clearance: forward low and reverse:
min. clearance = 2.79 mm (for carbon plates)
max. clearance = 5.21 mm (for carbon plates)
If clearance is more than 4.79 mm, add one
separator plate upon last separator plate.
Clearance: first and second:
min. clearance = 2.54 mm
max. clearance = 5.41 mm
7. Forward high clutch: 4 separator plates, 3 friction
plates and two 1-side friction plates.
Assembly see (6)
Clearance:
8. Disconnect clutch: 12 separator plates, 11 friction plates and two 1-side friction plates.
9.
10.
11.
12.
13.
14.
Assembly see (6)

Clearance:
Installation force of disc spring is 3280 N.
Be sure that shielded and sealed bearings are
mounted as shown.
Seals must be pressed in perpendicular upon
shaft axis from bearing side. Except lower rear
output.
Plug to be screwed in and torqued but without
Loctite.
Place the concave side of the spring of the first
clutch first disc against the wear sleeve of the
clutch piston.
Remaining 10 springs to be stacked alternately
reversed as shown.
Shipping strap: only used during shipment of the
individual transmission.
NOTE: check if safety valve and valve block are

tested before assembly.
15. Heat gears up to 150 C before assembling.
16. Parking brake.
17. Mounting: tighten locking nuts with 0.25 to 1.25
mm clearance between nuts and sleeves.
Adjustment: loosen the (2) adjustment locking
nuts (1 and 2). Put lever in correct position.
Tighten inner adjustment nut (2) with 11 Nm. Back
off inner adjustment nut (2).
Tighten outer locking nut (1) against inner adjustment nut (2). Clearance must be from 0.8 to 1.1
mm.
F27753
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TRANSMISSION DISASSEMBLY
Remove the oil filter.
Remove the filter adapter screws.
Remove the filter adapter with the O-ring.
Remove the drive plate screws.
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Remove the drive plates.
Remove the torque converter assy.
Remove the charging pump screws.
Use a bearing puller to remove the charging pump.
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Remove the charging pump assy, remove the Oring.
Remove the parking brake mounting screws.
Remove the parking brake assy.
Remove the upper output nut, the washer, the O-ring

and the flange.
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Remove the air breather.
Remove the control valve protection cover mounting

screws.
Remove the wiring connector mounting nut.
Remove the control valve protection cover and the

gasket.
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Remove the control valve mounting screws.
Remove the control valve assy: remove the by-pass

valve spool and the spring in the meantime.
Remove the auxiliary pump hole cover screws.
Remove the auxiliary pump hole cover and the gasket.
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Remove the pump drive shaft and the bearing assy.
Remove the pump drive shaft and the bearing assy.
Remove the upper output nut, the washer, the O-ring

and the flange.
Remove the converter housing to the transmission

case screws and the lock washers.
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Remove the transmission case plug.
Transmission case plug and gasket removed.
Spread ears on output shaft rear bearing retaining

ring. Hold snap ring open. Tap on the output shaft
and transmission case to remove the case from the
converter housing.
Lift transmission case from converter housing (using
lifting bracket).
Transmission case removed all drums and shafts remain in converter housing.
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Remove the transmission case to converter housing

gasket.
Remove the output shaft sealing rings.
Remove the output shaft rear bearing retaining ring.
Use bearing puller to remove the output shaft rear

bearing.
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Output shaft rear bearing removed.
Using bearing puller to remove the 2nd shaft rear

bearing.
2nd shaft rear bearing removed.
Using bearing puller to remove the input shaft rear

bearing.
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Input shaft rear bearing removed.
Remove the reverse and 1st shaft sealing rings.
Using bearing puller to remove the reverse and 1st

shaft rear bearing.
Reverse and 1st shaft rear bearing removed.
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Remove the forward low and forward high shaft

sealing rings.
Using bearing puller to remove the forward low and

the forward high shaft rear bearing.
Forward the low and forward high shaft rear bearing

removed.
Use bearing puller to remove the forward high gear

from the input shaft.
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Forward high gear removed.
Remove the baffle plate screws, remove the baffle

plates.
Remove the oil baffle to the converter housing

screws, do not remove the oil baffle from the output
shaft.
Remove the output shaft, the 2nd shaft and the oil
baffle at the same time.
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Loosen the suction tube retainer screw.
Remove suction tube retainer screw and lock washer.
Remove the suction tube retainer ring.
Remove the suction tube O-ring and the washer.
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Remove the output shaft front bearing retainer ring.
Remove the output shaft front assembly.
Remove the input shaft, the reverse and the forward

shaft at the same time.
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FORWARD HIGH CLUTCH DISASSEMBLY

Remove the clutch shaft sealing rings.
Remove the clutch gear outer needle bearing.
Remove the clutch gear.
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Remove the clutch gear inner needle bearing.
Remove the backing plate retainer ring.
Remove the clutch plate spacer.
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Remove the clutch disc backing plate.
Remove the one outer half disc.
Remove the inner and the outer discs.
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Compress the spring to remove the spring retainer

snap ring.
Remove the spring retainer snap ring.
Remove the clutch spring spacer.
Remove the clutch piston spring retainer.
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Remove the clutch piston spring.
Remove the clutch piston wear plate.
Remove the clutch piston assy.
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FORWARD LOW CLUTCH DISASSEMBLY

Use bearing puller to remove the front bearing and
gear.
Front bearing and gear removed.
Remove the gear retaining ring.
Use a bearing puller to remove the clutch gear and

the clutch gear outer bearing.
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Clutch the gear and the outer bearing removed.
Remove the spacer snap ring.
Remove the spacer.
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Use bearing puller to remove the clutch gear inner

bearing.
Clutch gear inner bearing removed.
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Remove the clutch gear inner bearing locating ring.

snap ring.
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FORWARD LOW CLUTCH ASSEMBLY

Install the clutch piston outer seal.
NOTE: ring must be sized before installing in clutch
drum. Sizing is best accomplished by rotating piston
while holding a round object against the new sealing
ring. Rotate piston until sealing ring is flush with outer diameter of the piston.
Install the clutch piston inner seal.

Install the clutch piston in clutch drum, use caution
as not to damage the sealing rings.
Install the clutch piston wear plate on the piston.
Install the clutch piston spring retainer.
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Install the clutch spring retainer snap ring.
Use a sleeve with the proper diameter to fit over

shaft and against retainer ring. A sharp blow with a
soft hammer will compress the spring and seat retainer ring.
Be sure ring is in full position in the groove.
Install one outer half disc, with friction material away

from the piston.
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Install one steel disc.

Alternate friction and steel discs until the proper
amount of discs are installed.
First and last discs are steel.
Install one outer half disc with friction material down.
Install the backing plate.
Install the backing plate snap ring.
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Install the spacer.
Install the spacer snap ring.
Install the inner bearing snap ring.
Install the clutch gear inner bearing.
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Tap the inner bearing into the place.
Install the clutch gear bearing locating rings.
Install the clutch gear sealing ring. Install the clutch

gear in the clutch drum. Align splines on clutch gear
with internal teeth of steel discs. Do not force this operation. Gear splines must be in full position with internal teeth of all inner discs.
Install clutch gear outer bearing.

Be sure that bearing shield is on the outside.
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Tap the outer bearing into the place.
Install the outer bearing snap ring.
Warm the gear to 150 C, install the gear.
Warm the front bearing to 120 C, install the bearing.
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FORWARD HIGH CLUTCH ASSEMBLY

Install the clutch outer seal.
Install the piston inner seal and install the clutch piston in clutch drum. Use caution as not to damage the
sealing rings.
Install the clutch piston wear plate on the piston.
Install the clutch piston return spring.
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Install the piston return spring retainer.
Install the spring retainer spacer.

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from the piston.

amount of discs are installed, first and last discs are
steel.
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Install the backing plate spacer.
Install the backing plate spacer retainer ring.
Install the thrust washer and the thrust bearing.
Install the clutch gear inner needle bearing.
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Install the clutch gear in the clutch drum. Align

splines on clutch gear with internal teeth of steel
discs.
Do not force this operation. Gear splines must be in
full position with internal teeth of all inner discs.
Install the clutch gear outer needle bearing.
Install the thrust washer and the thrust bearing.
Install the clutch shaft sealing rings.
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FIRST CLUTCH DISASSEMBLY

Remove the clutch gear bearing retaining ring.

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Remove the backing plate.
Remove the modulation spring.

bearing.
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Compress the clutch piston belleville washer spring.

Remove spring snap ring.
NOTE: force of disc spring is 3280N.
Spring retainer ring removed.
Remove the disc belleville washer spring.
Remove the clutch piston wear sleeve.
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REVERSE CLUTCH DISASSEMBLY

Use a bearing puller to remove the gear and the front
bearing.
Gear and front bearing removed.
Remove the clutch gear bearing retaining ring.

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Remove the spacer snap ring.
Remove the spacer.
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bearing.
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Remove the inner bearing locating ring.

snap ring.
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REVERSE CLUTCH ASSEMBLY

Install the clutch piston inner seal. Install the clutch

piston in clutch drum, use caution as not to damage
the sealing rings.
Install the piston wear plate.
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from the piston.
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Install the spacer.
Install the spacer snap ring.
Install the inner bearing snap ring.
Install the clutch gear inner bearing.
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Install the clutch gear bearing locating rings.
Install the clutch gear sealing ring. Install the clutch

gear in the clutch drum. Align splines on clutch gear
with internal teeth of steel discs. Do not force this operation. Gear splines must be in full position with internal teeth of all inner discs.
Install clutch gear outer bearing.
S WARNING
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Install the outer bearing snap ring.
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FIRST CLUTCH ASSEMBLY

Install the piston inner seal. Install the clutch piston

in the clutch drum. Use caution as not to damage the
sealing rings.
Install the clutch piston wear sleeve.
Install the piston return disc springs. First spring with

large diameter of bevel toward wear sleeve.
Alternate eleven (11) springs.
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Install the disc belleville washer spring retainer ring.
Compress the spring to install the spring retainer

ring.

from the piston.

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Install the modulator spring with large diameter up to

the backing plate.
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Install the clutch disc hub inner bearing.
Install the clutch hub bearing locating rings. Install

the clutch gear in the clutch drum. Align splines on
clutch gear with internal teeth of steel discs. Do not
force this operation. Gear splines must be in full position with internal teeth of all steel discs.
Install the clutch hub outer bearing.

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Tap the outer bearing into the clutch hub.
Install the outer bearing retaining ring.
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SECOND CLUTCH DRUM DISASSEMBLY

Press the upper output gear from the second shaft.
Press the gear from second shaft.
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Use bearing puller to remove the clutch hub and the

front bearing.
Remove the clutch shaft front bearing.
Remove the bearing washer.
Remove the clutch hub and the outer bearing.
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Use a bearing puller to remove the clutch hub inner

bearing.
Remove the clutch hub inner bearing.
Remove the backing plate snap ring.
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Remove the modulation spring.
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Compress the spring to remove the spring retaining

ring.
Remove the spring retaining ring.
Remove the spring retainer.
Remove the clutch piston return spring.
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Remove the piston wear plate.
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SECOND CLUTCH DRUM ASSEMBLY

Install the piston outer seal.

Install the clutch piston in the clutch drum.
Use caution as not to damage the sealing rings.
Install the piston return spring.
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Install the spring retainer.
Install the spring retainer snap ring.
Use a sleeve with the proper inner diameter to fit

over shaft and against retainer ring. A sharp blow
with a soft hammer will compress the spring and
seat retainer ring. Be sure ring is in full position in the
groove.

from the piston.
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Install the modulator spring with large diameter up to

the backing plate.
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Install the backing plate retainer ring.
Install the clutch hub inner bearing.
Tap the clutch gear inner bearing into the place.
Install the clutch hub bearing locating rings. Install

the clutch gear in the clutch drum. Align splines on
clutch gear with internal teeth of steel discs. Do not
force this operation.
Gear splines must be in full position with internal
teeth of all steel discs.
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Install the clutch hub outer bearing.
S WARNING
Install the bearing washer.
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Install the gear retaining ring.
Warm upper output gear to 150 C install gear.
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OUTPUT SHAFT DISASSEMBLY

Remove the oil baffle screws and the nuts.
Remove the oil baffle.
Remove the output shaft sealing rings.
Remove the output shaft gear retaining ring.
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Press the output gear from the shaft.
Remove the output gear.
Remove the oil baffle from the output shaft.
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Remove the backing plate snap ring.
Remove the backing plate spacer.
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Compress the spring to remove the spring retaining

ring.
Remove the spring retaining ring.
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Remove the spring retainer.
Remove the piston wear plate.
Remove the piston assy.
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OUTPUT SHAFT ASSEMBLY

Install the piston outer seal.

Install the clutch piston in the clutch drum.
Use caution as not to damage the sealing rings.
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Install the spring retainer.
Install the spring retainer snap ring. Use a sleeve

with the proper inner diameter to fit over shaft and
against snap ring. A sharp blow of a soft hammer will
compress the spring and the seat retainer ring. Be
sure ring is in full position in the groove.

from the piston.

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Install one half disc with friction material down.
Install the backing plate spacer.
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Install the oil baffle on the output shaft.
Install the output gear retaining ring.
Install the output gear retaining ring.
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Install the output shaft sealing rings.
Install the rear oil baffle on the output shaft.
Install the oil baffle mounting screws, the washer

and the nuts and tighten the nuts to the specified
torque (Use Loctite 243).
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DISCONNECT SHAFT DISASSEMBLY

Use bearing puller to remove the disconnect shaft
front bearing.
Remove the front bearing.
Remove the front bearing retaining ring.
Remove the clutch hub from the shaft.
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Remove the clutch hub locating ring from the shaft.
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DISCONNECT SHAFT ASSEMBLY

Install the bushing if necessary.
Install the clutch hub locating ring.
Install the clutch hub on the shaft.
Install the front bearing retaining ring.
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Install the front bearing on the shaft.
Tap the bearing on the shaft.
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PUMP DRIVE SHAFT DISASSEMBLY

Remove the rear bearing snap ring.
Use bearing puller to remove the rear bearing.
Remove the rear bearing from the shaft.
Remove the sealing ring from the shaft.
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PUMP DRIVE SHAFT ASSEMBLY

Install the sealing ring on the shaft.
Install the rear bearing on the shaft.
Tap the bearing into the place.
Install the rear bearing retainer ring.
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INPUT SHAFT DISASSEMBLY

Remove the input shaft rear sealing ring.
Remove the forward high gear retaining ring.
Remove the forward low gear retaining ring.
Remove the input shaft front sealing ring.
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Use bearing puller to remove the input shaft front the

bearing.
Remove the input shaft front bearing.
Remove the input shaft front bearing retaining ring.
Remove the forward low gear retaining ring.
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Press the forward low gear from the shaft.
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INPUT SHAFT ASSEMBLY

Install the forward low gear retaining ring.
Install the forward low gear retaining ring.
Install the input shaft front bearing retaining ring.
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Install the input shaft front sealing ring.
Warm the input shaft front bearing to 120 C, install

the bearing.
Turn the shaft and install the input shaft forward high
gear retaining ring.
Install the input shaft rear sealing ring.
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CONVERTER HOUSING ASSEMBLY

Install the safety valve ball spring and the plug.
Install the by-pass valve ball spring and the plug.
Install the output shaft front oil seal.
Using suitable seal installer, tap seal in place.
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Install the input shaft into housing and in the meantime install reverse and first shaft (they have to be installed together). Using caution as not to damage
any of the first shaft sealing rings.
Install the forward low shaft and the high shaft into
the housing. Use caution as not to damage the sealing rings.
Install the disconnect shaft assembly into the housing.
Open the bearing retaining ring. Tap the shaft into

the place. Be sure ring is in the groove.
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Install the upper and the lower output at the same

time.
Do not force this operation, be sure discs of disconnect are in full position. Using caution as not to damage any of the lower shaft sealing rings.
Install the baffle plate, the mounting screws, the

washers and the nuts. Tighten the nuts to the specified torque. (Use Loctite 243).
Install the baffle plate, the mounting screws, the

washers and the nuts. Tighten the nuts to the specified torque. (Use Loctite 243).
Install the oil baffle, the mounting screws and the

washers. Tighten the screws to the specified torque.
(Use Loctite 243).
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Install the O-ring, the spacer and the snap ring on

the suction tube. Install the suction tube into the
housing. Be sure ring is in the groove.
Install the suction tube retainer, the mounting screw

and the lock washer (Use Loctite 243).
Tighten the mounting screw to the specified torque.
Install the output shaft rear bearing retaining ring.
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Warm the forward high gear to 150 C, install the

gear.
Warm the upper output rear bearing to 120 C, install

the bearing.
Warm the reverse and 1st shaft rear bearing to

120 C, install the bearing.
Warm the input shaft rear bearing to 120 C, install

the bearing.
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Warm the forward low and high shaft rear bearing

to 120 C, install the bearing.
Warm the lower output shaft rear bearing to 120 C,

install the bearing.
Install the output shaft rear bearing retaining ring.
Install the gasket and the clutch pressure O-rings (4)

into the O-ring grooves.
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TRANSMISSION ASSEMBLY
Remove the lower output bore plug. Position the
transmission case on the converter housing (using
lifting bracket).
Using spreading type snap ring pliers, spread ears

on output shaft rear bearing retaining ring. Hold
snap ring open. Tap the transmission case into the
place.
Tap the dowel pin in the transmission case and the

converter housing.
Install the transmission case to the converter housing mounting screws and the lock washers.
Tighten the mounting screws to the specified torque.
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Using spreading type snap ring pliers, spread ears

on output shaft rear bearing retaining ring. Hold
snap ring open, pry or lift output shaft. Be sure retaining ring is complete in the bearing groove. (Using
a lifting eye or screw M12).
Install the hole plug and the gasket.
Tighten the plug to 13.6 - 20.3 Nm.
Position the lower output bore plug and the tap bore
plug into the place.
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Position the upper output seal.
Tap the seal into the place.
Install the upper output flange, the O-ring, the washer and the nut and tighten the nut to 339 - 407 Nm.
Install the pump drive shaft assy into the housing.
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Install the pump drive shaft rear bearing retaining

ring.
Install the pump hole cover, the gasket, the screws

and the lock washers.
Tighten the pump hole cover screws.
Install the pump and the O-ring into the converter

housing.
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Install the pump mounting screws and the lock

washers, then tighten the screws.
Install the converter assembly on the input shaft.
Install the drive plates on the converter.
Install the drive plate screws and the lock washers,

then tighten the screws.
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Install the filter adapter, the O-ring, the lock washers

and the mounting screws.
Tighten the screws.
Install the oil filter and tighten to 30 - 38 Nm.
Install the output shaft front flange, the O-ring, the

washer and the nut. Tighten the nut to 339 - 407 Nm.
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Position the parking brake, install the mounting

screws (See parking brake adjustment).
Install the by-pass valve spool into the solenoid

housing and the spring into the transmission case.
Place the control valve on the transmission case.
Install the control valve mounting screws and the

lock washers, tighten the screws.
Position the wiring connector in the valve protection

cover.
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Install the gasket and the valve protection cover

mounting screws, then tighten the screws.
Install the air breather and tighten to 34 - 41 Nm.
Install the wiring connector nut and tighten to 6 -8 Nm.
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Replacement and adjustment of parking brake
19
20
19
18
2
1
17
15
14
12
21
16
13
11
10
F27750
Z Loosen two adjustment locking nuts (4 and 5) enough to slide each torque plate (16 and 18) away from disc
far enough to provide clearance to remove old pads assembly and install new ones. (It may be necessary to
remove one or both nuts).
Z Collapse pad retraction spring (21) and remove from brake head assembly.
Z Slide torque plates (16 and 18) away from disc, move pads assembly (17) out of pockets, and remove from
the brake head assembly from the side.
Z Install new pads assembly (17) in each torque plate (16 and 18).
Z Install pad retention spring (21) into brake head assembly. Be sure springs feet are positioned properly in
holes in both pads assembly (17).
Z Tighten inner adjusting nut (5) until firm contact is made with the disc by the pads. Torque to 11 Nm make
certain lever is in proper operating position for application.
Z Back off inner adjusting nut (5) and check that disc is free to move (total clearance 0.8 - 1.1 mm).
Z Tighten outer locking nut (4) against inner adjusting nut to lock adjustment bolt in place. Torque to 61 - 75 Nm.
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2.13 SPECIAL TOOLS
P/N CNH
380000676
DESCRIPTION
Lifting tool
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2.14 FAULT FINDING

STALL TEST
Use a stall test to identify transmission, converter, or
engine problems.
TRANSMISSION PRESSURE CHECKS
Transmission problems can be isolated by the use
of pressure tests. When the stall test indicates slipping clutches, then measure clutch pack pressure to
determine if the slippage is due to low pressure or
clutch plate friction material failure.
In addition, converter charging pressure and transmission lubrication pressure may also be measured.
MECHANICAL AND ELECTRICAL CHECKS
Prior to checking any part of the system for hydraulic
function (pressure testing), the following mechanical
and electrical checks should be made:
Z Check the parking brake for correct adjustment.
Z Be sure all lever linkage is properly connected and
adjusted in each segment and at all connecting
points.
Z The controls are actuated electrically. Check the
wiring and electrical components.
Z Be sure that all components of the cooling system
are in good condition and operating correctly.
The radiator must be clean to maintain the proper
cooling and operating temperatures for the engine
and transmission. Air clean the radiator, if necessary.
Z The engine must be operating correctly. Be sure
that it is correctly tuned and adjusted to the correct
idle and maximum no-load governed speed specifications.
HYDRAULIC CHECK
Also, before checking the transmission clutches,
torque converter, charging pump, and hydraulic circuit for pressure and rate of oil flow, it is important to
make the following transmission fluid check:
Check oil level in the transmission. The transmission oil must be at the correct (full) level. All clutches
and the converter and its fluid circuit lines must be
fully charged (filled) at all times. See note below.
NOTE: the transmission fluid must be at operating
temperature of 82 - 93 C to obtain correct fluid level
and pressure readings. Do not attempt to make
these checks with cold oil.
To raise the oil temperature to this specification it is
necessary to either operate (work) the vehicle or run
the engine with converter at stall. (Refer to converter stall procedure).
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PROBLEM
Low clutch pressure
CAUSE
CORRECTION
Low oil level

Clutch pressure regulating valve
stuck open
Faulty charging pump
Broken or worn clutch shaft or
piston sealing rings
Fill to proper level.

Clean valve spool and housing.
Low charging pump output
Low oil level

Suction filter plugged
Defective charging pump

Clean the pump section.
Replace the pump.
Overheating
Worn oil sealing rings
Remove, disassemble and

reassemble the converter.
Replace.
Clean the cooler.
Replace cooler lines.
Worn charging pump

Low oil level
Dirty oil cooler
Restriction in cooler lines
Replace the pump.

Replace seal rings.
Noisy converter
Worn charging pump

Worn or damaged bearings
Replace.
A complete disassembly will be
necessary to determine which
bearing is faulty.
Lack of power
Too low engine rpm. The

converter stalls
See Overheating and make
same checks
Adjust the engine governor.

Make corrections as explained in
Overheating.
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2.15 FAULT FINDING

Before attempting any fault finding ensure you have
a suitable multimeter for checking component continuity. When fault finding remember that with an electrical concern it is often a minor fault that may have
occurred and could be as simple as:
Z Poor continuity between connector pins.
Z Condensation in the connectors.
Z Disconnected cables.
Z Damaged or broken wires all of which could result
in a no drive situation but easily remedied when
found and corrected.
It should also be remembered that mechanical problems could result in fault codes appearing on the
LED display.
F28292
INDICATION OF FAULTS
In case a fault is present during normal operation
and is detected by the microprocessor, both the TLED and N-LED may be blinking in some way as
shown in the table below.
NOTE: on an open circuit or on a battery connection

(+), at the ON/OFF outputs, a detection is made only
when the corresponding output is in the OFF position.
Also a short to ground is only detected while the output is on.
4
F28358
LED - T
(Orange)
LED - N
(Red)
CONDITION
SITUATION
Off
Off
Normal operation
Off
On
Normal operation - N selected
Off
Blinks
Blinks Normal operation - N selected/speed

too high
On
Off
Diagnostic mode was activated at power up
On
On
Controller in RESET - malfunction
Fault
On
Blinks
Self calibration in progress
Blinks
On
Last fault currently shown on display
Fault
Blinks
Blinks slower
Input fault detected
Fault
Blinks
Blinks in phase
Non critical output fault detected
Fault
Blinks
Blinks faster
Safety critical output fault detected
Fault
Blinks fast
Blinks out of phase
System shutdown - Neutral till power down
Fault
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LED DISPLAYED FAULTS

If a fault is, or there have been (intermittent faults)
present, a detailed fault display can be selected by
placing: the Powershift lever in neutral position and
pressing the kickdown button. The indicated fault on
the LED display can then be localized by using the
table below, until power down.
FAULT GROUP
The faults are displayed using 2 LEDs on the 8 LED
display. Faults are displayed as 3 subgroups Group A:
FAULT SUBGROUP A
GROUP INDICATION
Input related
LED 1 blinks red
Output related
LED 2 blinks red
Other
LED 3 blinks red
FAULT GROUP
LED (B)
Within each group several faults are possible. The

second LEDs position - Group B, indicates the fault
area, where the colour indicates the fault type. Typically an open circuit condition is shown using an orange LED where a short circuit condition is indicated
with a red LED. Once the fault code has been determined proceed to fault codes.
FAULT GROUP
LED (A)
B
F28359
PROBLEM
FAULT CODE
None
None
No fault active
1 Red
4 Orange
Shift lever input fault
F1
1 Red
5 Orange
Speed sensor open circuit
F2
1 Red
5 Red
Speed sensor in short
F3
1 Red
7 Green
Battery over voltage
F4
2 Red
4 Orange
Open circuit on one or both direction outputs
F5
2 Red
4 Red
Direction output forced to plus - critical fault
F6
2 Red
5 Orange
Other output open circuit
F7
2 Red
5 Red
Red Other output short circuit
F8
2 Red
6 Orange
Modulation output open circuit
F9
2 Red
6 Red
Modulation output short circuit
F10
3 Red
5 Red
Start-up fault - limp home mode selected
F11
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SHIFT LEVER INPUT FAULT CODE F1

Perform input test
This test is used to verify operation of the shift lever
and its inputs.
In this mode driving is possible.
Blinks
NOTE: the gear position indicators on the microprocessor top cover are used to display the test information.
Blinks
Slower
Blink
Blinks
4
F28360
INPUT TEST REQUIREMENTS: with the powershift

lever in forward position and set to upshift (keep the
lever in this position during start-up), start the machine. The microprocessor shifts to the input test
mode. As shown in the table below placing the shift
lever in different positions in this mode illuminates its
respective LED (only 2 at the same time).
IMPORTANT: self test modes can only be started
WHILE POWERING UP (ignition on). Leaving the
self test mode is done by switching OFF the power
of the Microprocessor (ignition off).
POWERSHIFT LEVER POSITIONS - WITH UP
AND DOWNSHIFT SELECTION
Neutral
Neutral and upshift
Neutral and downshift
Forward
Forward and upshift
Forward and downshift
Reverse
Reverse and upshift
Reverse and downshift
Operate disconnect button on loader lever
Operate 4WD switch on instrument panel
Foot brake test + 4WD
Foot brake test + 4WD
Transmission in automatic mode
Temperature and speed sensor: to test disconnect
lead on the sensor and short to ground
*= Auto transmission only
**= Auto/Manual override
LED NUMBER
2
3
1
2
3
1
2
3
1
5 (*) (**)
6 (*) (**)
6 (**)
7 (*)
7 (*)
8
LED COLOUR - DISPLAYED = Ok

RED
RED
RED
GREEN
GREEN
GREEN
ORANGE
ORANGE
ORANGE
GREEN
GREEN
GREEN
RED
RED
RED
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Key on power
YES
T-LED Blinks
N-LED Blinks Slower
YES
Select neutral and push kickdown
button:
= LED 1 red
= LED 4 orange
YES
Input fault: forward/reverse
Replace the powershift lever unit
YES
Test with new powershift
lever unit fitted
NO
NO
No input fault
Other input fault

YES
Check through
F2, F3, F4 or F11
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SPEED SENSOR / FAULT CODE F2 AND F3

A fault indication on the display is given to warn of
this problem.
If a speed sensor fault is detected the microprocessor will modify its behaviour in the following areas:
Z no upshifts will be allowed above second gear.
Z direction change while in F3 or F4: the actual reversal is preceded by a downshift sequence until
second gear is obtained.
Z 4WD braking remains operative.
Blinks
Slower
Blink
Blinks
Blinks
NOTE: that the system response in this case is identical to the response in case of a power supply overvoltage.
Speed sensor test using the turbine speed display
NOTE: a lamp test is performed prior to the speed
sensor test and monitors all LEDs are operational.
SPEED SENSOR TEST REQUIREMENTS: powershift lever to be in reverse position, twist to upshift
(keep the shift lever in this position during power up)
turn the ignition on and start the engine.
With engine running return Powershift lever to neutral position and then place lever in forward and twist
to upshift. Increase engine speed and compare with
the table opposite.
IMPORTANT: self test modes can only be started
self test mode is done by switching OFF the power
to the Microprocessor (ignition off).
The LED corresponding with the table opposite illuminates to indicate the torque converter turbine
speed and increases with engine revs.
NOTE: application of the foot brakes during this test
will reduce the turbine speed to zero.
F28361
Turbine rpm
LED
1 blinks
0 - 249
1 on
250 - 499
2 on
500 - 749
3 on
750 - 999
4 on
1000 - 1249
5 on
1250 - 1499
6 on
1500 - 1749
7 on
1750 - 1999
8 on
above 2000
8 blinks
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Speed sensor test okay

YES
NO
Key on power
YES
T-LED Blinks
N-LED Blinks Slower
YES
End

button:
= LED 1 red
= LED 5 orange (F2)
NO
= LED 1 red
= LED 5 red (F3)
YES
NO
YES
Repair
NO
No input fault
NO
Other input fault

YES
Check wires from speed sensor CV pin A to Powershift

lever unit pin A or CV pin J to pin U, and continuity test.
Does it test OK?
Refer to F1, F4
or F11
YES
Check speed sensor has it failed
NO
CV15 (A)
Change lever unit

NO
CV07 (J)
100
If static is 0.6 - 0.8 V

or 1.3 - 1.5 V
+ 12 V
YES
F28371
Replace sensor
If static is not 0.6 - 0.8 V or
1.3 - 1.5 V
1
F28370
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FAULT CODE F4 / BATTERY OVERVOLTAGE

(17 V +)
Over voltage
Even power supply levels up to 30 V will not damage
system components.
Above a power supply of 17 Vdc:
Group Fault 1 - Fault code 7.
NOTE: the speed sensor system will not operate
when an overvoltage is present.
Blinks
Blinks
Slower
Blink
Blinks
4
F28362
Above a power supply of 24 Vdc:

the analogue signals are not reliable to convert any
more.
Over voltage: when the voltage exceeds 17 Vdc.
Action of the Microprocessor:
Z no upshifts above second gear.
Z direction change while in Forward 3 or Forward 4:
the actual reversal is preceded by a downshift sequence until second gear is obtained.
+ 24 VDC
F28363
Z brake switch activation always engages 4WD.

NOTE: with voltages below 8 Vdc, the microprocessor enters the reset mode.
Intermittent power loss
After power is restored, the microprocessor goes
through the reset mode.
- 8 VDC
F28364
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Key on power
YES
T-LED Blinks
N-LED Blinks Slower
YES
button:
1 red - 7 green
YES
NO
No input fault
Other input fault

Check through F1, F2, F3 or
F11
NO
Check battery voltage above

17.7 Volts
YES
Check dual battery connection is

parallel and okay
YES
Repair or
replace
NO
Check alternator output

NO is it correct
YES
NO
Disconnect and
reconnect correctly
YES
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FAULT CODE F5 AND F6 / OPEN CIRCUIT

DIRECTION OUTPUTS
Direction selection related outputs (E06-Pin P,

E07-Pin N):
A short to plus is considered as a critical fault. Shorts
to plus usually result in being blocked in either Forward or Reverse. If both are on simultaneously, the
transmission Behaviour depends on the state of a
mechanical interlock inside the transmission.
Blinks
Blinks
Faster
Blink
Blinks
4
F28365
In this case the Microprocessor normally turns on

the pressure modulator (E03-Pin T). This results in
immediate selection of neutral regardless of the origin of the fault. Indeed even in case the short to plus
is applied externally, this response effectively blocks
the transmission in neutral.
If however at the time the fault was detected a fault
was also present on the pressure modulator, the microprocessor reverts to shutdown mode and remains this way until power is removed. Shutdown
mode is a state in which power is removed from the
microprocessor outputs by opening the internal redundant shutdown path.
This only helps if the fault was caused by the microprocessor internally.
Additionally, during program execution, critical variables are continuously checked for contents integrity.
Gearshifts
low/high solenoid:
inactive = forward high is selected
active = forward low is selected
SHIFT
DIAGRAM SOLENOIDS
FORWARD
1 2 3 4
reverse/n
REVERSE
12
XX
forward/n
low/high
XXXX
1st/2nd
XX
B
C
D
E
P
R
F
A
N
V
S
G
M
U
T
L
K
J
F4288
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During the output test LEDs 1234567 one by one are used and by
colour identifies the possible component at fault.
Red = Short circuit
Yellow = open circuit or short to battery plus
YES
YES
NO
Green= No fault
found
Identify component by LED

1 - Forward solenoid
2 - Reverse solenoid
3 - 1/2 Solenoid
4 - High/low forward travel solenoid
5 - 4WD/RWD solenoid
6 - Direction modulation solenoid
7 - Range modulation solenoid
YES
Identify component by LED

1 - Forward solenoid
2 - Reverse solenoid
3 - 1/2 Solenoid
4 - High/low forward travel solenoid
5 - 4WD/RWD solenoid
6 - Direction modulation solenoid
7 - Range modulation solenoid
YES
Example: LED 1(red) forward solenoid

output shorted to ground or a
component.
Check component and continuity of the
cables and connectors
Example: LED 2 (orange) reverse

solenoid output open circuit or shorted
to battery plus
Check component and continuity of the
cables and connectors output test
Output test
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OUTPUT FAULT - LED COLOUR

OUTPUT TEST REQUIREMENTS: powershift lever
to be in forward position, twist clockwise to downshift
and turn ignition on.
In this mode, driving is not possible, since all microprocessor outputs remain off until the test mode is
left.
The colour and number of the LED indicates its status:
COLOUR
STATUS
GREEN
Output OK
ORANGE
Output not connected

or shorted to battery
plus
RED
Output shorted to
ground (or to another
output)
Output test - Fault by LED Number

The LED numbers correspond to the connector output wires as follows:
Example:
LED 1 = Forward solenoid - colour
Orange = (Output not connected or shorted to battery plus)
LED
NUMBER
OUTPUT
WIRE
OUTPUT
FUNCTION
E06
Forward solenoid
E07
Reverse solenoid
B
C
D
E
P
R
F
A
N
V
S
G
M
U
T
L
K
J
F4288
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Key on power
YES
T-LED Blinks
N-LED Blinks Faster
NO
Safety critical
output
YES
Select neutral and push kickdown button
(F5) open circuit: 2 red - 4 orange
NO
YES
All LEDs green
and OK
NO
Repair or
replace
Repair or
replace
Repair or
replace
Check the forward cable

of the powershift lever:
YES is it faulty?
NO
NO
YES
Perform output test - fault

NO
found?
YES
YES
Led 1 orange
YES
Other output fault

forced to plus
(F6) 2 red - 4 red
Led 2 orange
YES
Other LEDs are

orange
YES
Proceed to F7, F8,
F9 or F10
Check the reverse cable

of the powershift lever: is
it faulty?
YES
NO
Check forward travel solenoid

YES resistance: is it faulty?
NO
Check reverse travel solenoid

resistance: is it faulty?
NO
YES
Check internal wires in forward travel

YES solenoid: are they faulty?
NO
Check internal wires in reverse

travel solenoid: are they faulty?
NO
YES
Replace the
powershift lever
unit
F28372
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FAULT CODE F7 AND F8 / OUTPUT FAULT STATUS BY LED COLOUR

OUTPUT TEST REQUIREMENTS: powershift lever
to be in forward position, twist clockwise to downshift
and turn ignition on.
In this mode, driving is not possible, since all microprocessor outputs remain off until the test mode is
left.
The colour and number of the LED indicates its status:
COLOUR
Blinks
Blinks
in Phase
Blinks
Blinks
STATUS
GREEN
Output OK
ORANGE
Output not connected

or shorted to battery
plus
RED
Output shorted to
ground (or to another
output)
F28367
Output test - Fault by LED Number

The LED numbers correspond to the connector output wires as follows:
Example:
LED colour Red and numbered 3 = 1/2 solenoid output shorted to ground.
LED
NUMBER
OUTPUT
WIRE
OUTPUT
FUNCTION
E04
1/2 Solenoid
E05
High/low forward
travel solenoid
E09
B
C
D
AWD/RWD
solenoid
P
R
F
A
N
V
S
G
M
U
T
L
K
J
3
F4293
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Key on power
YES
T-LED Blinks
N-LED Blinks in phase
YES
Non critical output

fault
NO

(F7) open circuit: 2 red - 5 orange
NO
Other output fault

(F8) short circuit 2 NO
red - 5 red
YES
YES
All LEDs green
and OK
NO Perform output test - fault found?

YES
Led 3 orange or red

YES
Repair or
replace
Repair or
replace
YES
NO
YES
Other LEDs are

orange
YES
Led 5 orange or
red
YES
Led 4 orange or
red
YES
Proceed to
F9 or F10
Check 1/2 solenoid: is

Check the AWD/RWD
solenoid: is it faulty?
YES it faulty?
Check the high/
NO
NO
low solenoid: is it YES
YES faulty?
NO
Check internal and
external wiring of
affected solenoids: are
YES they faulty?
NO
Replace the
powershift lever unit
5
F28373
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FAULT CODE F9 AND F10 / DIRECTION

MODULATION OUTPUT SHORT OR OPEN
CIRCUIT
A fault on this output is considered as a problem potentially reducing transmission life.
For this reason while a fault is persistent, the allowable direction change speed limit is decreased gradually (10%) each time a direction change was
inhibited, down to a minimum of 20% of the maximum allowable shift speed.
After a while, this can result in a severely degraded
performance (only low speed reversals are possible), but it has the advantage that the driver cannot
be surprised by a sudden performance loss, which
could constitute a safety hazard in itself.
281
Blinks
Blinks
in Phase
Blinks
Blinks
4
F28368
Direction Modulation Solenoid (E03) Pin T

The variable Current solenoid for direction modulation is connected to the modulation Common Plus
(Pin K) at one side and to (Pin T) at the other side.
A programmable current is increased or reduced to
the solenoid controlling the modulating pressure.
No current corresponds to maximum pressure.
Approximately 1 Amp corresponds with no pressure.
B
C
D
E
P
R
F
A
N
V
S
G
M
U
T
K
J
F4296
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Key on power
YES
T-LED Blinks
N-LED Blinks in phase
YES
button (F9) 2 red - 5 orange
NO
(F10)
2 red - 6
NO
red
YES
NO
YES
All LEDs green
and OK
Repair or
replace
NO
Direction modulator open

circuit
YES
Check solenoid
YES resistance: is it faulty?
NO
Repair or
replace
No fault
Other non critical

output fault, F7 or F8
Direction modulator short

circuit
YES
Check solenoid resistance:
is it faulty?
YES
NO
Check internal and external wiring of the direction

YES modulation solenoid: are they faulty?
NO
Replace the
F28374
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283
FAULT CODE F11 / START UP FAULT LIMP

HOME SELECTED
Internal faults
At power up a series of integrity checks is done.
If a fault is detected:
Z and the fault prevent operation as a transmission
controller: the microprocessor locks itself in a reset
state.
Z and controlling the transmission is still possible: the
microprocessor reverts to limp home mode.
R
Blinks
N
Slower
Blink
Blinks
T
Blinks
4
F28369
Limp Home mode

Defaulted to if an internal problem is detected at
power up.
This model automatically selected at power up if the
integrity tests show that EPROM parameters are corrupt, but the microprocessor can still function as a
transmission controller (other components integrity
are intact).
In this mode the user can operate the transmission in
either direction in 1st and 2nd. There are no protections: all shifts are unmodulated.
Key on power
YES
T-LED Blinks
N-LED Blinks Slower
NO
No input fault
YES
NO (F11) 3 red - 5 red
YES
Replace the
NO
Other output fault 2 red - 6 red

Refer F1, F2, F3 or F4
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284
FAULTS OTHER F12

NOT IDENTIFIED BY THE LEDS
There may be situations when an individual component develops a fault but it is not highlighted by the
LEDs. If a component is in doubt proceed to input
test as follows:
Perform Input test:
This test is used to verify the inputs.
NOTE: the gear position indicators on the microprocessor top cover are used to display the test information.
INPUT TEST REQUIREMENTS: the powershift lever must be in forward position. Set it to upshift and
start the machine. The microprocessor shifts to the
input test mode.
As shown in the table below placing the shift lever in
different positions in this mode illuminates its respective LED.
IMPORTANT: selftest modes can only be started
selftest mode is done by switching OFF the power of
the microprocessor.
CHECKING OF INPUT REQUESTS
LED NUMBER
LED COLOUR DISPLAYED
Confirm input test is okay (lever forward, neutral, reverse) and in order check as below:
1. Operate disconnect button on loader lever
GREEN = OKAY
2. Operate 4WD switch on instrument panel and foot brakes
GREEN = OKAY
3. Foot brake test on later models
RED = OKAY
4. Temperature and speed sensor: to test disconnect lead on

the sensor and short to ground
RED = OKAY
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F12
Key on power
YES
Perform input test and analyse
faults if possible fault found
NO
Repair or
replace
Possible input switch faults:

4WD - Request
Brake - Request
YES
Declutch - Request
Direction - Request
Speed/Temp sensor
F13
Key on power
YES
Repair or
replace
Perform output test and check

range modulation LED 7 (wire
E08)
YES Green = Okay
Orange = Open circuit
Red = Short circuit
285
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LIMP HOME LEAD

In the event of a total failure of the microprocessor
such as a serious cab or loom fire the vehicle can be
moved by using the limp home lead to by-pass the
microprocessor.
Tool No. - 380000715
Mounted to the left hand side and to the top of the

transmission is the microprocessor loom connector.
Disconnect the damaged loom and connect the limp
home lead in its place.
F11834
Connect the plug end into the 12 V auxiliary socket

or any available 12 V supply.
F11835
When seated in the cab, start the engine and make

sure that the personnel stays away from the machine. Select forward or reverse travel on the switch
and the machine will move accordingly.
NOTE: when using the limp home lead only second
gear (forward or reverse) is selectable no other
gearshift or modulation is available.
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580SR
580SR+
590SR
695SR

1. FRONT AXLE 2WD CARRARO ................................................................................................................. 3
1.1 SPECIFICATIONS ................................................................................................................................. 3
1.3 FAULT FINDING.................................................................................................................................. 24
2. FRONT AXLE 4WD CARRARO ............................................................................................................... 26
2.1 SPECIFICATIONS ............................................................................................................................... 26
2.3 FAULT FINDING.................................................................................................................................. 77
3. FRONT AXLE 4WS CARRARO ............................................................................................................... 80
3.1 SPECIFICATIONS ............................................................................................................................... 80
3.3 FAULT FINDING................................................................................................................................ 137
4. SPECIAL TOOLS...................................................................................................................................... 140
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1.
FRONT AXLE 2WD CARRARO
1.1
SPECIFICATIONS
TYPE
Front steering axle, model 26.00
F27349
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GREASING AND LUBRICATION
DESCRIPTION
POSITION
Oil level plug
Air breather
Level, fill and drain plug for reduction gear oil
Oil drain plug
Greasing points
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Before draining the oil from axle housing, use the

breather (2) to release possible internal pressure.
S WARNING
Risk of violent oil ejection.
To drain the oil remove the level plug (1) and the
drain plug (4).
S WARNING
Drain all oil.
Clean the drain plug (4) and tighten to the requested
torque.
Always use the oil breather (2) to release possible

internal pressure.
Unscrew the level plug (1) and fill to the bottom of
the level plug hole with the specified oil.
Wait to allow the oil to flow through the axle. Check
oil level and fill to the specified level if necessary.
Screw the level plug (1) to the prescribed torque.
Before draining the oil from the wheel hub, rotate it

so that the plug (3) is in the lowest possible position
and partially unscrew the plug to release any possible internal pressure.
Remove the plug and drain the oil.
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6
1.2

FRONT AND REAR SUPPORT
1
7
2
4
5
8
15
1
13
11
10
14
12
8
9
F27351
Disassembly
Remove the rear support (10) from the differential
support.
10
F27352
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Remove the O-ring (11) from the rear support (10).

NOTE: this is a destructive operation for the O-ring.
11
10
F27353
Remove the bolt (8) with the lube nibble (9).

Remove the bush (12) from the rear support (10).
12
10
9
F27354
Remove the bushes (1) from the rear support (10).
10
F27355
Remove the bush (13) and the thrust washer (14)

from differential support only if necessary.
NOTE: it is advisable to heat the bush (13) to make
easy this operation; this is a destructive operation
for the bush.
14
13
F27356
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Take the front support (2) out from the axle housing
(6).
2
6
F27357
Remove the bolt (8) with the lube nibble (9).

Remove the bush (3) from the front support (2).
Remove the bushes (1) from front support (2).
F27358
Remove the bush (4) and the thrust washer (5) from
axle housing (6) only if necessary.

for the bush.
F27359
Assembly
Insert the thrust washer (14) into the differential support.
Heat the bush (13) at 110 120 C then assemble it
to the differential support.
NOTE: if necessary assemble the bush (13) with a
pad and a hammer.
14
13
F27356
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Apply sealant on the bushes (1) contact surface.

Assemble the bushes (1) to the rear support (10)
with a pad and a hammer.
10
F27355
Assemble the bush (12) in the rear support (10).
S WARNING
Align the bush hole with the bolt (8) hole.
Mount the bolt (8).
12
10
F27360
Lubricate with grease a new O-ring (11).

Insert the O-ring (11) in the rear support (10).
11
10
F27353
Insert the rear support (10) on the differential support.
S WARNING
Do not damage the O-ring when inserting the rear
support on the axle housing.
Tighten the bolt (8) to the request torque and tighten
the lube nibble (9).
10
8
9
F27361
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Insert the thrust washer (5) into the front support

seat.
Heat the bush (4) at 110 120 C then assemble it
to the axle housing (6).

pad and a hammer.
F27359

Assemble the bushes (1) to the front support (2) with
a pad and a hammer.
F27362
Assemble the bush (3) into the front support (2) with
a suitable driver and a hammer.
S WARNING
Mount the bolt (8).
F27363
Insert the front support (2) on the axle housing (6).

Tighten the bolt (8) to the request torque and tighten
the lube nibble (9).
2
6
8
9
F27364
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11
STEERING CYLINDER
19
10
21
17
11
12
20
15
18
16
13
14
5
4
3
F27227
Disassembly
Loosen the nut (1) with enough turns till it is protruding over the threaded pin end of the tie rod (3).
Hit the nut (1) with an appropriate hammer in order
to separate the tie rod (3) from the swivel housing
(2).
S WARNING
Dont beat on the threaded pin end of the tie rod (3).
NOTE: this is a destructive operation for the nut (1).
Repeat the whole sequence at the other side.
3
2
1
F27228
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Remove the tie rods (3) and (12) by loosening the

nuts (4) and (11) with a suitable wrench, then check
their conditions.
Unscrew the fastening screws (6) and take the
steering cylinder (7) out of its housing; if necessary,
use a rubber hammer.
Remove only parts that need to be overhauled and/
or replaced.
11
12
10
7
Remove the cylinder head (15) from the cylinder

body (19) and remove it from the rod (17).
Remove the rod (17) from the cylinder body (19).
Remove all the seals and O-rings (13, 14, 16, 18, 20
and 21) from the cylinder body (19), the cylinder
head (15), and the rod (17).
F27229
21
19
13
14
16
20
18
17
15
F27230
Assembly
Assemble new seals and O-rings (13, 14, 16, 18, 20
and 21) on the cylinder head (15), on the piston rod
(17) and on the cylinder body (19).
19
13
14
21
16
20
18
17
15
F27231
Assemble the cylinder head (15) on the rod (17).

Slide the pre-assembled rod (17) into the cylinder
body (19).
17
15
19
F27232
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13
Assemble the tie rods (3) and (12), the ball joints (5)
and (10), the nuts (4) and (11) to the ends of the rod
(17), then tighten to the requested torque.
11
6
12
10
7
17
3
Install the steering cylinder (7) already assembled

on the central body.
Assemble and tighten the screws (6) to the specified
torque.
F27233
F27504
Align the swivel housing (8) with the axle.

Screw the tie rod (12) so that its ball joint can be inserted into the swivel housing (8).
11
12
NOTE: it is important to unscrew the locknut (11) to

carry out this operation.
Repeat the whole sequence of the mentioned operations to the other side.
Assemble the ball joint of the tie rod (3) into its housing in the swivel housing (2).
Assemble and tighten the locknut (1) to the specified
torque.
F27235
1
2
F27236
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Screw the locknuts (4) and (11) of the tie rods (3)
and (12) only when the toe-in adjustment has been
carried out.
11
12
F27238
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15
WHEEL HUB
19
12
18
11
18
20
21
10
17
16
6
22
14
13
2
15
12
F27365
Disassembly
Unscrew and remove the fastening screws (1) of the
cover (2). Remove the cover (2) and the O-ring (6).
6
2
1
F27366
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Loosen and remove the screws (3). Remove the

thrust washer (4).
Remove the wheel hub (7) using levers and a hammer to facilitate the operation.
NOTE: collect the bearing cone (5).
7
5
F27368
Position the wheel hub (7) on a flat surface and remove the seal ring (9) with a lever.
NOTE: destructive operation for the seal ring (9).
Remove the bearing cups (5) and (8) using a hammer and a suitable drift.
Remove the bearing cone (8) from the swivel housing end, using a suitable extractor.
9
8
F27255
Unscrew and remove the fastening bolts (12) from

the upper (11) and lower (13) king pin.
S WARNING
Before removing the king pins (11) and (13), secure
the swivel housing (10) to a rope or a hoist or to any
other supporting device; observe all current safety
regulations to guarantee the operators safety.
12
11 13
10
Remove the king pins (11) and (13).

F27370
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17
Remove the swivel housing (10) from the axle shaft.
10
F27371
Remove the thrust washers (16) and (19) with the

bushes (17) and (18).
19
18
17
16
F27372
Assembly
If it has been previously removed, reassemble the
steering stop composed by the screw (15) and nut
(14).
14
NOTE: do not tighten the nut (14) until the steering

angle adjustment has been done.
15
F37917
Insert the thrust washers (16) and (19) and the

bushes (17) and (18).
19
18
17
16
F27372
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If ball joints (21) and (22) have been previously removed, reassemble them on the upper (11) and lower king pin (13).
22
21
13
11
F27374
Secure the swivel housing (10) with a belt or a rope

to a hoist or to any other supporting device.
Protect the splined end of the axle shaft by winding
it with an adhesive tape to avoid damage to the seal
ring.
Assemble the swivel housing (10) on the axle shaft.
10
F27371
Assemble the king pins, the lower (13) and the upper (11), and tighten the retaining screws (12) to the
requested torque.
12
11 13
F27375
Assemble both bearing cups (5) and (8) to their

wheel hub (7) housings using the special tool
380002663 under a press or with a hammer.
Insert the seal ring (9) into the wheel hub (7) with the
special tool 380002227 and a hammer.
NOTE: do not lubricate the seal ring (9).
9
7
8
7
F27376
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Assemble the bearing cone (8) on the swivel housing (10).

Assemble the wheel hub (7) on the swivel housing
(10) and insert the bearing cone (5).
19
10
F27377
Assemble the thrust washer (4). Screw the screws

(3).
Assemble a new O-ring (6). Assemble the cover (2)

and screw two screws (1). Tighten the screws (1) to
the specified torque.
6
2
1
F27366
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20
TOE-IN / STEERING ANGLE
11
1
11
3
F27339
Toe-in
Put two equal 1 m long linear bars on the wheel
sides and lock them with two nuts on the wheel hub
stud bolt.
S WARNING
The two bars should be fixed on their middle so that
they are perpendicular to the supporting surface
and parallel to the pinion shaft axis; align the two
bars.
500 mm
500 mm
F27340
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21
Measure the distance in mm M between the bars

ends with a tapeline.
NOTE: keep the minimum value, swinging the
measurement point.
F27341
Check that the difference of the measurements between the wheel hubs diameters ends is within the
requested tolerance range.
The nominal toe-in value (A) is referred to the external diameter of the wheel hubs flange, therefore the
measured value (M) at the bars ends must be related to the ratio between length of the bar and flange
diameter:
0
nominal toe-in = A - 2
A -02
measured toe-in = M - 5
M -05
F27342
If toe-in is incorrect, operate with two wrenches on

the guide rods (1) screwing in and out the two joint
tie rods (3) equally till the toe-in is within the requested tolerance.
3
3
F27343
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After adjusting, screw in the locknuts (2) of the guide

rods (1) to the requested tightening torque.
F27344
Steering angle adjustment

Use the same bars assembled for the toe-in adjustment and a long bar perfectly leaned over the machined part of the central body (pinion side), so that
the two bars form an acute angle at the maximum
steering.
F27345
Adjust a protractor to the requested angle and position it on the long bar.
Move a wheel side till it forms, with the two bars, the
angle fixed by the protractor.
F27346
Adjust the mechanical steering stop, screwing in or

off the stop screw (4), locking it with the locknut (5)
to the requested tightening torque.
F27347
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23
Steer completely towards the other side and repeat

the same operation.
F27348
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24
1.3

FAULT FINDING
PROBLEM
CAUSE
Wheel vibration; front tyre resistance; half shaft

breakage
Steering is difficult; vehicle goes straight while its
turning
Transmission excessively noisy
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent noise
1. Incorrect installation / defective axle
Correct installation or repair or replace the differential in case it does not survive any one of the test phases.
2. Overloading / incorrect weight distribution
Remove excessive weight and redistribute load, following instructions related to the vehicle.
3. Different rotation radius of the tyres
If one tyre has a smaller radius, it will cause partial wheel slipping when force is applied. The other tyre with
bigger radius will have to support all the work. Replace the tyre or adjust pressure to have same radius on both
tyres.
4. Broken half shaft
It is not advisable to operate the vehicle with a broken half shaft. It is acceptable to move the vehicle (engine
off unloaded) a few metres away only.
5. Bent half shaft
Replace the half shaft.
6. Incorrect wheel adjustment
Verify group integrity and wheel side bearings.
Adjusting according.
7. Damaged or worn axle parts
Check the bearings conditions, etc.
Replace whenever necessary.
8. Contamination in the axle box or incorrect assembly of parts
Look for foreign particles.
Check assembly of the various parts of the axle.
9. Incorrect use of the product
See the vehicle Manufacturers instructions once again.
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PROBLEM
Axle beam body bent
CAUSE
Vehicle overloaded
25
CORRECTION
Replace axle beam body.
Vehicles accident
Load bump
Worn out or pitted bearings
Insufficient lubrication
Replace bearings.
Contaminated oil
Use proper lubrication, fill up to right

level and replace at recommended
intervals.
Excessive use
Normal wear out
Oil leakage form gaskets and
seals
Prolonged functioning at high

temperature of the oil
Replace the gasket and the

matching surface if damaged.
Oil gasket assembled incorrectly
Use correct lubrication and replace

at recommended intervals.
Seal lip damaged

Contaminated oil
Bent or broken half shaft
Vehicle intensively operated or

overloaded
Replace.
Half shaft broken at wheel side
Wheel support loose
Replace.
Beam body bent
Check that wheel support is not

worn out or wrongly adjusted.
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2.
FRONT AXLE 4WD CARRARO
2.1
SPECIFICATIONS
TYPE
F27203
POWERSHIFT
POWERSHUTTLE
RATIO
12.8
12.333
13.714
14.308
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27
LUBRICATION AND GREASING

Differential oil capacity
6.5 litres
Reduction gear oil capacity, on each side
0.7 litres
Oil specification:
use recommended oil enriched in additives
Note: do not use synthetic or vegetable oil without consent of the axle
manufacturer
Amber
Mastertran NH 410 C
5
5
5
F27205
DESCRIPTION
POSITION
Oil level plug
Air breather
Oil drain plug
Greasing points
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Copyright
Before draining the oil from axle housing, use the oil
S WARNING
drain plug (4).
S WARNING
Drain all oil.
torque.

internal pressure.
Screw the plug (1) to the prescribed torque.
Before draining the oil from the reduction gear, rotate it so that the oil plug (3) is in the highest position
[position A] and partially unscrew the plug to release
any possible internal pressure.
Rotate the wheel end so that the plug (3) is toward
the ground [position B].
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Rotate the wheel end so that the hole (3) is in the position shown in figure.
Fill to the bottom of the fill plug hole with specified
oil.
Tighten the plug (3) to the requested torque.
29
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30
165 Nm
95 Nm 120 Nm
80 Nm
25 Nm 120 Nm
8 Nm
150 Nm
300 Nm
8 Nm
120 Nm
95 Nm
13 Nm
169 Nm
120 Nm
57 Nm
266 Nm
165 Nm
10 Nm
8 Nm
84 Nm
60 Nm
8 Nm
84 Nm
F27211
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2.2
31
21
18
20
17
15
16
19
14
12
9
8
6
5
13
11
10
7
4
2
1
F27212
Disassembly
Remove the nut (3) and the bolt (2) and extract the
flange (1) from the pinion shaft end (14).
14
3
1
2
F27213
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Loosen the bolt (4).

Take the rear support (5) out from the differential
support.
4
F27214
Remove the O-ring (6) from the bush (8) in rear support (5).
NOTE: this is a destructive operation for the O-ring.
5
7
F27215
Remove the bolt (4).

8
4
F27216
F27217
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33
Remove the cover (11) from differential support with

a lever.
11
F27218
Remove the O-ring (12) and the seal ring (13) from
the cover (11).
13
12
NOTE: destructive operation for the seal rings.
11
F27219

from differential support only if necessary.
for the bush.
10
9
F27220

Take the front support (20) out from the axle housing (15).
20
15
19
F27221
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Remove the bolt (19).

21
20
18
19
F27222

from axle housing (15) only if necessary.
15
16

for the bush.
17
F27223
Assembly
Insert the thrust washer (10) into the differential support.
Heat the bush (9) at 110120 C then assemble it to
the differential support.
If necessary assemble the bush (9) with a pad and
a hammer.
10
9
F27220
Assemble the seal ring (13) to the cover (11) with

the special tool 380002432 and a hammer.
Assemble the new O-ring (12) into the cover (11).
Lubricate the O-ring (12) and the seal ring (13).
13
12
11
F27219
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35
Assemble the cover (11) to the differential support.
11
F27218

Assemble the bushes (6) to the rear support (5) with
a pad and a hammer.
F27217
S WARNING
Mount the bolt (4).
8
4
F27216

5
7
F27215
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S WARNING
support on the central body.
Tighten the bolt (4) to the requested torque.
4
F27214
Assemble the flange (2) to the pinion shaft end (14).

Lock the flange (1) with the bolt (2) and the nut (3).
Tighten the nut (3) to the requested torque.
14
3
2
F27213
Insert the thrust washer (16) into the front support

seat.
Heat the bush (17) at 110120 C then assemble it
15
16

pad and a hammer.
17
F27223

Assemble the bushes (21) into the front support (20)
21
20
F27224
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37
Assemble the bush (18) into the front support (20)

with a suitable driver and a hammer.
S WARNING
20
18
Mount the bolt (19).
19
F27225
Insert the front support (20) on the axle housing.

Tighten the bolt (19) to the requested torque.
20
19
F27226
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38
STEERING CYLINDER
19
10
21
17
11
12
20
15
18
16
13
14
5
4
3
F27227
Disassembly
Beat on the nut (1) with an appropriate hammer in
order to disjoin the tie rod (3) from the swivel housing (2).
S WARNING
3
2
1
F27228
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Remove the tie rods (3) and (12) by loosing the nuts
(4) and (11) with a suitable wrench, then check the
conditions.
steering cylinder (7) out of its housing, if necessary
use a rubber hammer.
or replaced.
39
11
12
10
7

F27229
21
19
13
14
16
20
18
17
15
F27230
Assembly
and 21) on the cylinder head (15), on the rod (17)
and on the cylinder body (19).
19
13
14
21
16
20
18
17
15
F27231

body (19).
17
15
19
F27232
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Copyright
and (10), the nuts (4) and (11) to the ends of the rod
(17), then tighten to the requested torque.
11
12
10
7
17
3

Assemble and tighten the screws (6) to the requested torque.
F27233
F27234

Screw the tie rod (12) so that its ball joint can be inserted into the swivel housing (8).
11
12

Assemble the ball joint of the tie rod (3) into its housing in the swivel housing (2).
torque.
F27235
1
2
F27236
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Screw the locknuts (4) and (11) of the tie rods (3)
and (12) only when the toe-in adjustment has been
carried out.
11
41
12
F27238
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42
REDUCTION GEAR
10
9
8
7
6
5
4
2
1
3
F27239
Disassembly
Drain the oil completely from the planetary carrier.
F27240
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Unscrew and remove both fastening screws (3) of

the planetary carrier cover (1).
43
3
1
F27241
Remove the planetary carrier cover (1), the swivel

housing and collect the relevant O-ring (5).
Position the planetary carrier (1) on a workbench
and check its wear conditions.
F27242
If necessary, replace the gears as follows:

Z remove the snap rings (10) on every pin (4);
Z remove the triangular plate (9);
Z extract the gears (8) from the pins;
Z collect the bearings (7) and check their conditions;
Z collect the thrust washer (6).
NOTE: with the new gears it is advisable to assemble new needles.
10
4
9
F27243
Assembly
Collect all reduction gear parts: the planetary carrier
cover (1), the thrust washers (6), the needle bearings (7), the gears (8), the triangular plate (9) and
the snap rings (10) of every pin.
10
1
F27244
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Position the planetary carrier cover (1) on a workbench.

Insert the thrust washers (6) and the gears (8) into
the planetary carrier pins.
Insert the needle bearings (7) into the gears (8).
10
NOTE: grease well the needles.

Assemble the triangular plate (9) and the related
snap rings (10).
8
F27245
Insert a new O-ring (5) on the planetary carrier cover

(1).
Assemble the planetary carrier cover (1) onto the
wheel hub.
1
5
F27246
Assemble the screws (3) and tighten to the specified

torque.
3
1
F27241
To up the oil on the wheel hub.

Assemble the plug (2) onto the planetary carrier
cover (1) and tighten to the specified torque.
1
F27247
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WHEEL HUB
19
18
28
27
24
12
10
13
22
14
23
11
15
16
17
20
25
26
21
F27248
Disassembly
Insert a lever between the swivel housing (14) and
the axle shaft and fit into the cardan shaft.
With the lever, push the cardan shaft in the direction
of the wheel hub to allow the removal of the snap
ring.
S WARNING
Do not damage the cardan shaft.
14
F27249
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Remove the snap ring (1) from the cardan shaft.

Collect the washers (2) and (3) of the cardan shaft.
F27250
Unscrew and remove the fastening screws (5) from

the ring gear carrier (7).
7
5
F27251
In order to extract the ring gear carrier from its housing, screw in two of the just removed screws (5) in
the threaded extraction holes.
Extract and remove the ring gear carrier (7) together
with the ring gear (4).
5
7
4
F27253
Remove the retaining ring (8) and separate the ring

gear carrier (7) from the ring gear (4).
Only if necessary, remove the bushes (6) from the
ring gear carrier using a hammer and the special
tool 380002223.
8
6
7
4
F27252
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15
NOTE: collect the bearing (9).
11
9
F27254
Remove the bearing (12) from the swivel housing
end using a suitable extractor.
9
8
F27255
Unscrew and remove the fastening bolts (19) and

(17) from the upper (18) and lower (16) king pin.
S WARNING
17 19
16 18
14

F27256
Extract the swivel housing (14) from the axle shaft

and the cardan shaft.
14
F27257
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Remove the spacer (27) from the upper king pin

housing.
27
F27258
Position the swivel housing (14) on a flat surface

and extract the seal ring (23) with a lever.
22
Turn the swivel housing and take the bush (22) out,
using a suitable drift and a hammer.
14
23
F27259
Assembly
(20).
20
21
F27260
Insert the bush (22) into the swivel housing (14) with
the special tool 380002660 and a hammer or a
press.
Insert the seal ring (23) into the swivel housing (14)
with the special tool 380002661 and a hammer.
Grease carefully the seal ring (23).
23
14
22
F27261
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Assemble the spacer (27) in the upper king pin

housing.
27
F27258
If the cone (15) of the spherical joint has been previously removed, reassemble it to the lower king pin
(16) using the special tool 380002662 under a
press.
Grease carefully the seats of king pin (16) and (18)
with specific grease.
Position the belleville washers (25) and (28) on the
king pin (16) and (18) housings.
15
16
28
25
18
25
F27262

ring.
Assemble the swivel housing (14) on the axle shaft.
14
F27257
Assemble the king pins, the lower (16) and the upper (18), and tighten the retaining screws (17) and
(19) to the requested torque.
17 19
16 18
F27263
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Insert the seal ring (13) into the wheel hub (11) with
13
12
11
11
F27264
Assemble the bearing (12) on the swivel housing

(14) end.
(14) and fit the bearing (9).
14
12
F27265
Position the ring gear carrier (7) on a workbench

and force the bushes (6) to the carrier (7) surface
level with the special tool 380002223.
At least two bushes (diametrically-opposed) should
be set slightly higher than the carrier surface level to
be used as dowel pins.
F37835
Preassemble the ring gear carrier (7) and the ring

gear (4) with the retaining ring (8).
8
7
4
F27267
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Assemble the ring gear carrier assy on the wheel

hub using the two projecting bushes as dowel pins
and screw in the relevant screws in order to put the
ring gear in contact with the wheel hub.
F27268
Insert all the hub dowel bushes (6) completely with

Apply sealant on fastening bolts (5) thread.
Assemble the screws (5) fastening the ring gear carrier (7) and tighten to the specified torque.
5
7
F27269
The special operation Set Right of the bearings (9)

and (12) does not require preload or backlash adjustment. Anyway, before assembling new components check the indicated dimensions.
A= 11.975 12.025
B= 52.229 52.279
C= 20.000 20.100
C
B
F27270
Insert a lever between the swivel housing and the

axle shaft and fit into the cardan shaft.
of the wheel hub to allow an easier fitting of the retaining ring.
F27271
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Assemble the thrust washers (2) and (3) on the end

of the cardan shaft.
Insert the snap ring (1) on the end of the shaft and
push it into its seat.
NOTE: check that the snap ring (1) is correctly fitted
in its seat.
Push in the cardan shaft completely.
F27250
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53
CARDAN SHAFTS
F27272
Disassembly
Remove the cardan shaft (6) from the axle shaft (1).
1
6
F27273
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Remove the seal rings (5) from the axle beam.

NOTE: destructive operation for the seal rings (5).
4
5
Remove the bush (4) from the axle beam only if the
wear conditions require this.
S WARNING
Be careful not to damage the bush seat.
F27274
Remove the upper king pin bush (2) and the bearing
cup (3) from the king pin seats using a suitable extractor only if wear conditions require it.
2
3
F27275
Assembly
Cool the upper king pin bush (2) and the bearing cup
(3) at a temperature lower than -100 C with liquid nitrogen.
S WARNING
Wear safety gloves.

Assemble the bush (2) on the upper king pin seat with
Assemble the bearing cup (3) on the lower king pin
seat with the special tool 380002662 and a hammer.
F27276
Assemble the bush (4) on the axle beam (1) with the
Assemble the seal ring (5) on the axle beam with the
NOTE: grease carefully the seal rings.
4
5
F27277
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Assemble the seal ring (5).
S WARNING
Positioning the seal ring (5) as in figure.
F27278
Insert the cardan shaft (6) into the axle shaft (1).
S WARNING
Be careful not to damage the seal ring.
1
6
F27273
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DIFFERENTIAL SUPPORT
13
12
11
10
6
14
9
8
5
4
1
3
F27282
Disassembly
Drain the oil completely from the differential.
Loosen and remove the screws (2) of the differential
support (1).
Remove the differential support (1) from the axle
housing (14).
S WARNING
Support the differential support with a rope or other
appropriate means.
14
2
1
F27283
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Loosen and remove the screws (9) to take out the

two ring nut retainers (8).
57
F27284
Before removing the bolts, mark both half-collars

(11) and the differential support with permanent reference marks to avoid inverting them during re-assembly. Mark the area between the ring nuts (3) and
(7) and the differential support (1) as well.
11
3
1
F27285
Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 and a wrench.
F27286
Remove the 4 screws (12) and remove both halfcollars (11).

NOTE: check that the bushes (10) remains in their
housings.
12
11
10
F27287
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Remove differential unit (5).

Remove the bearing (4) and (6) together with the differential assy.
S WARNING
Do not invert the bearing cone if the bearings are not

replaced.
F27288
Assembly
Assemble the bearings (4) and (6) on the differential
assy (5).
S WARNING
Do not invert the bearing cones if the bearings are
not replaced.
4
6
5
F27289
Assemble the differential assy complete with bearings on the differential carrier.
S WARNING
Check the correct assembly side of the ring gear.
F27290
Move the differential assy so that the ring gear is

placed against the pinion.
Check that all bushes (10) are in their housings and
position both half collars (11) on their seats using
the previously traced reference marks.
Lock both half collars with their fastening screws
(12).
12
11
10
F27291
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Assemble the adjuster ring nuts (3) and (7) to the

differential support.
Tighten both ring nuts (3) and (7) with special tool
380000406, till the backlash is eliminated and the
differential bearings are slightly preloaded.
Check that the differential bearings are well settled;
if necessary, knock slightly with a soft hammer, in
order to properly set the bearings in position.
59
F27292
Position a magnetic-base dial gauge on the differential support, so that the feeler stylus touches the surface of one tooth of the ring gear with a 90 angle.
F27293
Lock the pinion and move the crown gear alternatively and note the pinion-ring gear backlash, measured with the comparator.
Repeat the operation on 2 or more points (teeth), rotating the crown gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.180.25 mm
Carry out the adjustment by operating on the ring
nuts with the appropriate tool 380000406.
F27294
Adjust the ring nuts (3) and (7), remembering that:

(A)- if the measured backlash is greater than the
given tolerance range, unscrew the adjuster
ring nut (3) and screw in the adjuster ring nut (7)
by the same measure.
(B)- if the measured backlash is less than the given
tolerance range, unscrew the adjuster ring nut
(7) and screw in the adjuster ring nut (3) by the
same measure.
F27295
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Once the adjustment of the pinion-ring gear backlash has been carried out, check also that there is a
minimum preloading on the differential box bearings.
Repeat the whole sequence of the above mentioned
operations till the indicated conditions are reached.
F27293
Once the pinion-ring gear backlash has been established, measure the total preloading (T) of the bearings (pinion-ring gear system), using a
dynamometer, whose cord is wound on the splined
end of the pinion. The measured value should be
within the following range:
T = (P+3.90) (P+5.90) daN
where P is the effectively measured pinion preloading.
See section Pinion assembly.
S WARNING
F27296
All preloadings must be measured without the seal

ring.
If the measurement is not within the requested

range, check well the assembly of each component
and operate on the adjuster ring nuts (3) and (7) of
the differential support:
(A)- if the total preloading is less than the given
range, screw in both adjuster ring nuts (3) and
(7) by the same measure, keeping the pinionring gear backlash value unchanged.
(B)- if the total preloading is higher than the given
range, screw in both ring nuts (3) and (7) by the
same measure, keeping the pinion-ring gear
backlash value unchanged.
F27297
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Once all the adjustment operations have been completed, fit the ring nut retainers (8) and their screws
(9), tightening them to the requested torque.
9
8
F27298
Tighten the bolts (12) of both half collars (11) to the

requested torque.
12
13
F27299
Before matching surfaces, make sure that they are

perfectly clean, degrease and clean them with appropriate detergents.
Spread a film of adhesive on the contact surface between the axle beam (14) and the differential carrier.
13
14
NOTE: check that the two pins (13) are in their

housing.
13
F27300
Position the differential support (1) on the axle housing (14), and tighten the retaining screws (2) to the
requested torque.
14
2
1
F27301
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Bevel gear marking test
To test the marks of the bevel gear teeth, paint the

ring gear with red lead paint.
The marking test should always be carried out on
the ring gear teeth and on both sides.
F27302
OK -> Correct contact:

If the bevel gear is well adjusted, the mark on the
teeth surfaces will be regular.
Z -> Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in order to adjust the backlash.
X -> Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in order to adjust the backlash.
OK
F27303
Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.
F27304
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DIFFERENTIAL GROUP
Disassembly
Use an extractor to remove bearing (12).
12
F27306
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F27307
Loosen all fastening screws (1) of the ring gear (11).
11
S WARNING
This operation makes both differential half boxes
free, so take care not to lower the inner components.
F27308
Remove the ring gear (11) by means of a hammer.
11
F27309
Check the marking points (3) and (10) that will be

useful during the assemblage.
10
F27310
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Assemble the two half housings of the differential

unit (3) and (10).
Disassemble all the components.
Check the operating and wear conditions of the
components.
Assembly
Position a half housing (3) on a workbench and assemble all inner components: the discs (4), the
gears (5), the shaft (9), the gears (7), the spherical
washers (6) and the pin (8).

unit (3) and (10).
S WARNING
10
Carefully check that the marks of both differential

half housings coincide.
F27310
Assemble the ring gear (11) by means of a hammer.
11
F27314
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Apply Loctite 242 on the thread of screws (1).
1
F27316
Tighten the screws (1) to the specified torque.
1
F27315
Press the bearing (12) or assemble after preheating.
12
F27317
Press the bearing (2).
F27318
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PINION GROUP
Disassembly
Position the differential carrier in a vise.
Unscrew the ring nut (10) using the special tool
380002218.
NOTE: this operation will irretrievably damage the
ring nut (10).
10
F27320
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Remove the ring nut (10) and collect its washer (9).
9
10
F27321
Tap with a soft hammer to extract the pinion (1).
S WARNING
Take care not to lower the pinion (1).
Collect the washers (4) and (6), the spacer (5) and
the bearing (8).
5
1
6
4
Place the differential carrier (7) on a flat surface and

remove the bearing cups (3) and (8) using a drift and
a hammer.
F27322
8
F27326
To remove the bearing (3) of the pinion (1), use an

extractor.
Collect the bearing (3) and the shim (2).
3
2
1
F27324
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Check all pinion components for wear.
S WARNING
The ring nut (10) and the spacer (5) must be replaced when reassembling the unit.
10
F27325
Assembly
Place the differential support (7) on a workbench.
Assemble the bearing cups (3) and (8).
8
F27326
Prepare the kit consisting of the special tools called

false pinion 380002219 and false differential box
380000407 + 380000440 and a depth gauge.
F27327
Insert the bearing (3) and (8) in their housings.

Assemble the false pinion 380002219 and its ring
nut (10).
Tighten without exceeding the ring nut, till the backlash is eliminated.
8
3
10
F27328
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Install false differential box special tools

380000407 + 380000440 to the differential group
supports (7) and lock it with the half collar bolts.
F27329
Assembly diagram of the false differential box

tools 380000407 + 380000440 on the bearing differential support seats.
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 base of the bearing).
F27330
In order to determine the necessary thickness value

(S) between the pinion and the bearing, subtract the
value (V), stamped on the pinion head (V = requested conical distance), from the measured value (X).
S = X-V mm
F27331
Select the shim (2) of thickness value (S) among the

range of available shims.
F27332
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Remove the false differential box special tool from

the differential supports (7).
Remove the ring nut (10), the false pinion and the
bearing (3) and (8).
8
3
10
F27328
Once you have chosen and inserted the suitable

shim (2) with the chamfer against the gear, force the
bearing (3) into the pinion shaft (1) with the special
tool 380002224 under a press, making sure that it is
well set.
Insert the shims (4) and (6) and a new spacer (5).
3
2
NOTE: use always a new spacer (5).
F27334
Insert the pinion assy (1) into the differential support

housing (7) and the bearing cone (8).
To force the bearing into position (8), use a hammer.
It is advisable to offer resistance, for example a
sledge, to the beating force.
7
1
F27335
Insert the washer (9) and screw in a new ring nut

(10) on the pinion.
9
10
F27321
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72
Screw the ring nut (10) in, using the wrench

380002218 for ring nut and for pinion retainer.
S WARNING
The torque setting is given by the preloading measurement on bearings; tighten the ring nut (10) gradually.
NOTE: if the tightening is excessive, the collapsible
spacer must be replaced and the procedure repeated. When you check the preloading, it is advisable
to beat slightly both pinion ends with a soft hammer,
so as to help setting the bearings.
10
F27336
Carry out the preloading measurement P of the pinion taper roller bearings, using a dynamometer
whose cord is wound on the end of pinion spline.
The adjustment is carried out by increasing the ring
nut torque gradually, being careful not to exceed.
P = 9.213.7 daN
S WARNING
ring.
F27337
Once the requested preloading value is achieved,

stake the ring nut, using a hammer and a chisel.
F27338
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11
1
11
3
F27339
Toe-in
stud bolt.
S WARNING
bars.
500 mm
500 mm
F27340
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74

measurement point.
F27341
diameter:
0
A -02
M -05
F27342

3
3
F27343
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75

rods (1) to the requested tightening torque.
F27344

steering.
F27345
F27346

out the stop bolt (4), locking it with the locknut (5) to
the specified tightening torque.
F27347
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the same operation.
F27348
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77
FAULT FINDING
PROBLEM
CAUSE
10 11
Wheel vibration; front tyre resistance; half

shaft breakage
Steering is difficult; vehicle goes straight
while its turning
No differential action; jamming while
steering
Uneven wear of tyre
Friction noise
Vibration during forward drive, intermittent
noise
tyres.
5. Bent half shaft
6. Blocked differential
Abnormal functioning of the differential or breakage/blockage of command device. Verify assembly and all
components.
Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wearing
at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.
Check the condition of ring gear, pinion gear, bearings etc.
Look for foreign particles. Check assembly of the various parts of the axle.
10. Incorrect adjustment of the bevel gear set: Parts of the transmission worn out
(Transmission gears, U joints, etc.). Replace or adjust as required.
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PROBLEM
CAUSE
CORRECTION
Ring gear tooth broken on the

outer side
Excessive gear load compared to

the one foreseen
Incorrect gear adjustment
(excessive backlash)
Pinion nut loose
Replace bevel gear set.

Follow carefully the recommended
operations for the adjustment of the
bevel gear set backlash.
Ring gear tooth broken side
Load bump
Incorrect gear adjustment (insufficient backlash)
Pinion nut loose

Pinion or ring gear teeth worn
Contaminated oil
Incorrect lubrication or depleted
additives
Worn out pinion bearings that
cause an incorrect pinion axle
backlash and wrong contact
between pinion and ring

Use correct lubricants, fill up to the
right levels and replace according to
the recommended program.
Overheated ring and pinion teeth

See if gear teeth have faded

temperatures
Incorrect lubrication
Low oil level
Contaminated oil

program.
Pinion teeth pitting
Excessive use

Use correct lubrication, fill up to the
right level and substitute at recommended intervals.
Axle beam body bent
Vehicle overloaded
Vehicles accident
Load bump
Contaminated oil
Excessive use
Normal wear out
Pinion nut loose
Replace bearings.
right level and substitute at recommended intervals.

seals

Seal lip damaged
Contaminated oil
Replace the gasket or seal and

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79
Excessive wearing out of input

flange spline
Exhaustive use
Pinion nut loose
Pinion axle backlash
Replace the flange.

Check that the pinion spline is not
excessively worn out.
Replace bevel gear set if required.
Fatigue failure of pinion teeth

See if the fracture line is well
defined
(wave lines, beach lines)
Exhaustive use
Continuous overload
Pinion and ring teeth breakage
Crash load of differential components
Check and/or replace other differential components.
Side gear spline worn out

Replace all scratched washers
(Excessive backlash)
Excessive use
Replace differential gear group.

Replace half shaft if required.
Thrust washer surface worn out

or scratched
Contaminated oil
Use correct lubrication and fill up to

right level.
Replace at intervals recommended.
Replace all scratched washers and
those with a thickness by 0.1 mm
lower than the new ones.
Inner diameter of tapered roller

bearing worn out
Excessive use
Excessive pinion axial backlash
Contaminated oil
Replace bearing.
Check pinion axial backlash.
intervals.

overloaded
Replace.
Wheel support loose

Beam body bent
Replace.
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3.
FRONT AXLE 4WS CARRARO
3.1
SPECIFICATIONS
TYPE
F27378
POWERSHIFT
SELF LOCKING
RATIO
18.46
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Oil capacity
11.0 litres
Oil specification:
manufacturer
1
3
Akcela Nexplore MAT3525
5
F27379
DESCRIPTION
POSITION
Oil level plug
Air breather
Oil drain plug
Greasing points
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Before draining the oil from axle housing, use the

S WARNING
drain plug (4).
S WARNING
Drain all oil.
torque.

internal pressure.
Screw the level plug (1) to the prescribed torque.
Before draining the oil from the reduction gear, rotate it so that the oil plug (3) is in the highest position
[position A] and partially unscrew the plug to release
any possible internal pressure.
Rotate the wheel end so that the plug (3) is toward
the ground [position B].
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Rotate the wheel end so that the hole (3) is in the position shown in figure.
Fill to the bottom of the fill plug hole with specified
oil.
Tighten the plug (3) to the requested torque.
83
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3.2

21
18
22
17
15
16
19
23
5
11
14
1
3
12
10
13
2
F27380
Disassembly
Remove the nut (3) and the bolt (2) and extract the
flange (1).
1
3
F27381
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Remove the seal ring (13).
13
F27382
Unscrew the screws (11) and remove the flange

(12).
12
11
F27383

Take the rear support (5) out from the differential
support.
4
F27384
Remove the O-ring (7) from the rear support (5).

NOTE: this is a destructive operation for the O-ring
(7).
7
5
F27385
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Remove the bolt (4) and the lube nibble (9).

9
F27386
F27217
Remove the washer (10) from the differential support only if necessary.
10
F27387

Take the front support (20) out from the axle housing (15).
20
15
19
F27388
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87
Remove the O-ring (22).

Remove the bolt (19) and the lube nibble (23).
21
20
19
18
23
22
F27389
Remove the bush (17) and the washer (16) from the
axle housing (15) only if necessary.
17
15

for the bush.
16
F27390
Assembly
Insert the washer (10) into the differential support.
10
F27387

Assemble the bushes (6) to the rear support (5) with
a pad and a hammer.
F27217
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Copyright
S WARNING
Mount the bolt (4).
8
4
F27216

5
7
F27215
S WARNING
support on the central body.
Tighten the bolt (4) to the specified torque.

Assemble the lube nibble (9).
4
9
Insert the washer (16) into the front support seat.

Heat the bush (17) at 110120 C then assemble it
F27391
17
15

pad and a hammer.
16
F27390
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89

Assemble the bushes (21) to the front support (20)
21
20
F27224
Assemble the bush (18) into the front support (20)

with a suitable driver and a hammer.
S WARNING
20

Mount the bolt (19).
Assemble O-ring (22).
18
19
22
F27393
Insert the front support (20) on the axle housing.

Tighten the bolt (19) to the specified torque.
Assemble the lube nibble (23).
20
19
23
F27394
Assemble the flange (12) and fasten by tightening

the screws (11).
12
11
F27383
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Assemble the seal ring (13) use the special tool

380002225.
13
F27382
Assemble the flange (1). Lock the flange (1) with the
bolt (2) and the nut (3).
Tighten the nut (3) to the specified torque.
1
3
F27381
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91
STEERING CYLINDER
13
18
14
19
20
21
24
16
22
23
10
17
11
12
15
2
1
F27396
Disassembly
(2).
S WARNING
3
2
1
F27228
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Copyright

their conditions.
steering cylinder (7).
or replaced.
13
13
14
15

10
F27397
20
23
24
16
22
17
21
18
19
F27398
Assembly
23
24
16
22
17
21
20
18
19
F27392

body (22).
22
20
18
F27399
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93
and (10), the nuts (4) and (9) to the ends of the rod,
then tighten with a dynamometric wrench to the requested torque.
10
F27400

Assemble and tighten the screws (13) with dynamometric wrench to the requested torque.
Assemble bracket (14).

Screw in the tie rod (10) so that its ball joint can be
inserted into the swivel housing arm (11).
10

11
Insert the ball joint of the tie rod (3) into its housing
in the swivel housing (2).
torque.
F27402
1
2
F27236
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Screw the locknuts (4) and (9) of the tie rods (3) and
(10) only when the toe-in adjustment has been carried out.
10
F29526
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95
REDUCTION GEAR
4
11
9
10
8
7
6
5
1
3
2
F27404
Disassembly
F27240
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Copyright

3
1
F27241
Remove the planetary carrier cover (1) from the

wheel hub.
Position the planetary carrier cover (1) on a workbench and check its wear conditions.
F27405
If necessary, replace the gears as follows:

Z unscrew the screws (11) on every pin (4);
Z remove the washers (8) and (9);
Z extract the gears (7) from the pins;
Z collect the bearings (7) and check their conditions;
Z collect the washer (6).
10
11
F27406
Assembly
Position the planetary carrier cover (1) on a workbench. Insert the washers (5) and the gears (7) complete with the rollers (6) in the pins of the planetary
gear carrier.
Assemble the washers (8) and fasten them with the
pins (10).
Fit the washers (9) and screw in the screws (11) by
tightening them at the prescribed torque.
10
11
F29008
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wheel hub.
F27405

torque.
F27407

F27408
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98
WHEEL HUB
19
26
18
24
27
12
13
22
14
23
11
10
15
16
17
20
25
21
6
F27409
Disassembly
ring.
S WARNING
14
F27410
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99
F27250

7
5
F27251
In order to extract the ring gear carrier from its housing, screw in two of the just removed screws (5) in
the threaded extraction holes.
Extract and remove the ring gear carrier (7) together
with the ring gear (4).
5
7
4
F27253

wheel carrier using a hammer and the special tool
380002667.
8
6
7
4
F27252
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15
11
9
F27254
12

Remove the bearing cone (12) from the swivel housing end using a suitable extractor.
13
11
10
9
F27412

S WARNING
17 19
16 18
14

F27256

14
F27257
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101
Collect the belleville washers (25) and (26).
26
25
F27413

NOTE: this is a destructive operation for the seal
ring.
22
Turn the swivel housing and extract the bush (22)

14
23
F27259
Assembly
(20).
20
21
F27260
Insert the bush into the swivel housing (14) with the
special tool 380002668 and a hammer or a press.
23
14
22
F27261
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If ball joints (15) and (27) have been previously removed, reassemble them on the lower (16) and upper king pin (18).
Grease carefully the seats of king pin (16) and (18)
with specific grease.
Position the Belleville washers (25) and (28) on the
king pin housings.
27 15
26
18 16
25
F27414

ring.
14
F27257
17 19
16 18
F27263

Insert the seal ring (13) into the wheel hub (11) with
13
11
12
11
F27525
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103
Assemble the bearing (12) onto the swivel housing

end (14).
14
12
F27265

F37835

8
7
4
F27267

F27268
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Completely insert all bushes (6) using the special

tool 380002667 and a hammer.
Assemble the screws (5) fastening the ring gear carrier (7) and tighten to the specified torque.
5
7
F27269

of the wheel hub to allow an easier fitting of the snap
ring.
14
F27410
Assemble the thrust washers (2) and (3) on the end

of the cardan shaft.
Insert the snap ring (1) on the end of the splined hub
and push it into its seat.
in its seat.
F27416
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105
CARDAN SHAFTS
1
2
3
4
F27417
Disassembly
1
4
F27418
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Copyright
Remove the seal rings (3) from the axle beam (1).
2
3
Remove the bush (2) from the axle beam (1) only if
the wear conditions require this.
S WARNING
F27419
Assembly
Assemble the bush (2) on the axle beam (1) with the
2
3
NOTE: grease carefully the seal rings.
F27420
F27421
S WARNING
1
6
F27273
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107
DIFFERENTIAL SUPPORT GROUP
13
12
11
10
6
14
9
8
5
2
4
1
3
F27411
Disassembly
Drain the oil completely from the differential.
Loosen and remove the screws (2) of the differential
support (1).
Remove the differential support (1) from the axle
housing (14).
S WARNING
Support the differential support with a rope or other
appropriate means.
14
F27501
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Copyright
Loosen and remove the screws (9) to take out the

two ring nut retainers (8).
F27395
Before removing the bolts, mark both half-collars

(11) and the differential support with permanent reference marks to avoid inverting them during re-assembly. Mark the area between the ring nuts (3) and
(7) and the differential support (1) as well.
11
3
1
F27422
Unscrew the adjuster ring nuts (3) and (7) using tool
380000406 and a wrench.
F27423
Remove the 4 screws (12) and remove both halfcollars (11).

NOTE: check that the bushes (10) remains in their
housings.
12
11
10
F27424
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109
Remove differential unit (5).

Remove the bearing (4) and (6) together with the differential assy.
S WARNING
Do not invert the bearing cone if the bearings are not

replaced.
F27425
Assembly
Assemble the bearings (4) and (6) on the differential
assy (5).
S WARNING
Do not invert the bearing cones if the bearings are
not replaced.
4
6
5
F27289
Assemble the differential assy complete with bearings on the differential carrier.
S WARNING
Check the correct assembly side of the ring gear.
F27427
Move the differential assy so that the ring gear is

placed against the pinion.
Check that all bushes (10) are in their housings and
position both half collars (11) on their seats using
the previously traced reference marks.
Lock both half collars with their fastening screws
(12).
12
11
10
F27428
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Assemble the ring nuts (3) and (7) into the differential support.
Tighten both ring nuts (3) and (7) with special tool
380000406, till the backlash is eliminated and the
differential bearings are slightly preloaded.
Check that the differential bearings are well settled;
if necessary, knock slightly with a soft hammer, in
order to properly set the bearings in position.
F27429
Position a magnetic-base dial gauge on the differential support, so that the feeler stylus touches the surface of one tooth of the ring gear with a 90 angle.
F27293
Lock the pinion and move the crown gear alternatively and note the pinion-ring gear backlash, measured with the comparator.
Repeat the operation on 2 or more points (teeth), rotating the crown gear, so that to obtain an average
value.
Check if the measured backlash value is within the
requested range:
0.180.25 mm
Carry out the adjustment by operating on the ring
nuts with the appropriate tool 380000406.
F27430
Adjust the ring nuts (3) and (7), remembering that:

(A)- if the measured backlash is greater than the
given tolerance range, unscrew the adjuster
ring nut (3) and screw in the adjuster ring nut (7)
by the same measure.
(B)- if the measured backlash is less than the given
tolerance range, unscrew the adjuster ring nut
(7) and screw in the adjuster ring nut (3) by the
same measure.
F27295
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111
Once the adjustment of the pinion-ring gear backlash has been carried out, check also that there is a
minimum preloading on the differential box bearings.
Repeat the whole sequence of the above mentioned
operations till the indicated conditions are reached.
F27431
Once the pinion-ring gear backlash has been established, measure the total preloading (T) of the bearings (pinion-ring gear system), using a
dynamometer, whose cord is wound on the splined
end of the pinion. The measured value should be
within the following range:
T = (P+3.90) (P+5.90) daN
where P is the effectively measured pinion preloading.
See section Pinion assembly.
S WARNING
F27432

ring.
If the measurement is not within the requested

range, check well the assembly of each component
and operate on the adjuster ring nuts (3) and (7) of
the differential support:
(A)- if the total preloading is less than the given
range, screw in both adjuster ring nuts (3) and
(7) by the same measure, keeping the pinionring gear backlash value unchanged.
(B)- if the total preloading is higher than the given
range, screw in both ring nuts (3) and (7) by the
same measure, keeping the pinion-ring gear
backlash value unchanged.
F27297
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Once all the adjustment operations have been completed, fit the ring nut retainers (8) and their screws
(9), tightening them to the requested torque.
9
8
F27298
Tighten the screws (12) of both half collars (11) to

12
11
F27434
Before matching surfaces, make sure that they are

perfectly clean, degrease and clean them with appropriate detergents.
Spread a film of adhesive on the contact surface between the axle beam (14) and the differential carrier
(1).
13
NOTE: check that the two pins (13) are in their

housing.
14
F27435
Position the differential support (1) on the axle housing (14), and tighten the retaining screws (2) to the
requested torque.
14
F27501
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113
Bevel gear marking test

To test the marks of the bevel gear teeth, paint the
ring gear with red lead paint.
The marking test should always be carried out on
the ring gear teeth and on both sides.
F27302
OK -> Correct contact:

If the bevel gear is well adjusted, the mark on the
teeth surfaces will be regular.
Z -> Excessive contact on the tooth tip:
Approach the pinion to the ring bevel gear and then
move the ring bevel gear away from the pinion in order to adjust the backlash.
X -> Excessive contact at the tooth base:
Move the pinion away from the ring bevel gear and
then approach the ring bevel gear to the pinion in order to adjust the backlash.
OK
F27303
Movements to correct:
1 -> move the pinion for type X contact adjustment.
2 -> move the pinion for type Z contact adjustment.
F27304
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114
DIFFERENTIAL GROUP (STANDARD)
8
1
10
11
13
12
7
6
8
7
3
2
F27437
Disassembly
10
F27438
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115
F27307
11
S WARNING
F27308
11
F27309

F27439
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Copyright
Remove the gear (5) and the shim (4).
4
5
F27440
Remove the shaft (8), the gears (7) and the spherical washers (6).
F27441
12
13
F27442
Assembly
Apply a thin layer of Molicote G-n plus paste on the
half housings of differential (3) and (9).
S WARNING
Remove rests of dope.
F27443
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Apply a thin layer of Molicote G-n plus on the gears

(5) and (12) and on the gears (7).
117
7
5
12
7
F27444
Assemble the gear (12) and the shim (13).
12
13
F27442
Position the shaft (8), the gears (7) and the spherical
washers (6).
F27441
4
5
F27440
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Copyright

unit (3) and (9).
S WARNING

F27439
11
F27314
1
F27316
1
F27315
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119
10
F29010
F27318
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120
DIFFERENTIAL GROUP (SELF-LOCKING)
14
10
8
5
12
13
4
6
11
10
8
9
7
2
F27448
Disassembly
13
F27449
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121
F27307
14
S WARNING
F27446
14
F27450

12
F27451
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Copyright
Assemble the discs (4) and (5).
F27452
Remove the sun gear (11).
11
F27453
Remove the shaft (10), the gears (8) and the spherical washers (9).
10
F27454
F27455
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123
5
F27456
Assembly
12
S WARNING
F27457

8
7
11
8
F27458
Assemble discs (4) and (5).
5
F27456
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Assemble the gear (7).
F27455
Position the shaft (10), the gears (8) and the spherical washers (9).
10
F27454
Assemble the gear (11).
11
F37839
F27452
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125

unit (3) and (12).
S WARNING
12

F27451
14
F29320
1
F27316
1
F27315
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Copyright
13
F27460
F27318
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127
PINION GROUP
1
2
3
4
5
9
10
F27461
Disassembly
Position the differential carrier in a vise.
Unscrew the ring nut (10) using the special tool
380002218.
NOTE: this operation will irretrievably damage the
ring nut (10).
10
F27462
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Copyright
Remove the ring nut (10) and collect its washer (9).
9
10
F27463
Tap with a soft hammer to extract the pinion (1).
S WARNING
Take care not to lower the pinion (1).
Collect the washers (4) and (6), the spacer (5) and
the bearing (8).
5
1
6
4
Place the differential carrier (7) on a flat surface and

remove the bearing cups (3) and (8) using a drift and
a hammer.
F28106
3
7
8
F28107
To remove the bearing (3) of the pinion (1), use an

extractor.
Collect the bearing (3) and the shim (2).
3
2
1
F27324
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129
Check all pinion components for wear.
S WARNING
The ring nut (10) and the spacer (5) must be replaced when reassembling the unit.
10
F27325
Assembly
Place the differential support (7) on a workbench.
Assemble the bearing cups (3) and (8).
3
7
8
F28107
Prepare the kit consisting of the special tools called

false pinion 380002219 and false differential box
380000407 + 380000440 and a depth gauge.
F28108
Insert the bearing (3) and (8) in their housings.

Assemble the false pinion 380002219 and its ring
nut (10).
Tighten without exceeding the ring nut, till the backlash is eliminated.
3
8
10
F28109
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130
Install false differential box special tools

380000407 + 380000440 to the differential group
supports (7) and lock it with the half collar bolts.
7
F28110
Assembly diagram of the false differential box

tools on the bearing differential support seats.
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 base of the bearing).
F28111
In order to determine the necessary thickness value

(S) between the pinion and the bearing, subtract the
value (V), stamped on the pinion head (V = requested conical distance), from the measured value (X).
S = X-V mm
F27331
Select the shim (2) of thickness value (S) among the

range of available shims.
F27332
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131
Remove the false differential box special tool from

the differential supports (7).
Remove the ring nut (10), the false pinion and the
bearing (3) and (8).
3
8
10
F28109
Once you have chosen and inserted the suitable

shim (2) with the chamfer against the gear, force the
bearing (3) into the pinion shaft (1) with the special
tool 380002224 under a press, making sure that it is
well set.
Insert the shims (4) and (6) and a new spacer (5).
3
2
NOTE: use always a new spacer (5).
F27334
Insert the pinion assy (1) into the differential support

housing (7) and the bearing (8).
In order to force the bearing (8) into position, use the
It is advisable to offer resistance, for example a
sledge, to the beating force.
5
1
6
4
F28112
Insert the washer (9) and screw in a new ring nut

(10) on the pinion.
9
10
F27463
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132
Screw the ring nut (10) in, using the wrench

380003218 for ring nut and for pinion retainer.
S WARNING
The torque setting is given by the preloading measurement on bearings; tighten the ring nut (10) gradually.
NOTE: if the tightening is excessive, the collapsible
spacer must be replaced and the procedure repeated. When you check the preloading, it is advisable
to beat slightly both pinion ends with a soft hammer,
so as to help setting the bearings.
10
F27445
Carry out the preloading measurement P of the pinion taper roller bearings, using a dynamometer
whose cord is wound on the end of pinion spline.
P = 9.213.7 daN
S WARNING
ring.
F27432
Once the requested preloading value is achieved,

stake the ring nut, using a hammer and a chisel.
F27338
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133
F28113
Toe-in
stud bolt.
S WARNING
bars.
500 mm
500 mm
F27340
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134

measurement point.
F27341
diameter:
0
A -02
M -05
F27342

3
3
F27343
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135

rods (1) to the prescribed tightening torque.
F27344

steering.
F27345
F27346

out the stop bolt (4), locking it with the locknut (5) to
the specified tightening torque.
F27347
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Copyright

the same operation.
F27348
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3.3
137
FAULT FINDING
PROBLEM
CAUSE
10 11

shaft breakage
while its turning
steering
Uneven wear of tyre
Friction noise
noise
tyres.
5. Bent half shaft
components. Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wearing at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins
to kick.
10. Incorrect adjustment of the bevel gear set: Parts of the transmission worn out
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138
PROBLEM
CAUSE
CORRECTION

outer side

the one foreseen
Pinion nut loose

Load bump
(insufficient backlash)
Pinion nut loose

Contaminated oil
additives



temperatures
Low oil level
Contaminated oil

program.
Excessive use

right level and substitute at
recommended intervals.
Axle beam body bent
Vehicle overloaded
Vehicles accident
Load bump
Contaminated oil
Excessive use
Normal wear out
Pinion nut loose
Replace bearings.

seals

Seal lip damaged
Contaminated oil


flange spline
Exhaustive use
Pinion nut loose
Replace the flange.

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139

defined
Exhaustive use
Continuous overload
Crash load of differential

components
Check and/or replace other

differential components.

Excessive use


or scratched
Contaminated oil

right level.

bearing worn out
Excessive use
Contaminated oil
Replace bearing.
intervals.

overloaded
Replace.
Wheel support loose

Beam body bent
Replace.
Check that wheel support is not worn
out or wrongly adjusted.
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140
4.
SPECIAL TOOLS
P/N CNH
USE
2WD
4WD
4WS
380000406
Disassembly/assembly of differential ring nuts
380000407 +
380000440
Calculation of pinion shims
380002213
Assembly of seal ring in the wheel hub
380002218
Disassembly/assembly of pinion rings
380002219
Calculation of pinion shims
380002222
Assembly of bearing cups in the wheel hub
380002223
Disassembly and assembly bushings in the crown retainer hub
380002224
Assembly of pinion bearing
380002225
Assembly of front flange seal connection
380002226
Assembly of bushing in the half beam
380002227
Assembly of seal ring in the wheel hub
380002432
Assembly of sliding block in the swivel housing
380002660
Assembly of bushing in the swivel housing
380002661
Assembly of seal ring in the swivel housing
380002662
Assembly of spherical joint on lower and upper king pin
380002663
380002664
Assembly of bushing in the seat of the upper king pin
380002665
Assembly of bushing in the half beam
380002666
Assembly of seal ring in the half beam
380002667
Disassembly/Assembly of bushings in the crown retainer hub
380002668
380002669
380002670
Assembly of seal ring in the half beam
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580SR
580SR+
590SR
695SR

1. REAR AXLE 2WS ......................................................................................................................................... 3
1.1 DESCRIPTION AND OPERATION....................................................................................................... 3
1.2 SPECIFICATIONS ................................................................................................................................. 6
1.4 FAULT FINDING.................................................................................................................................. 27
2. REAR AXLE 4WS CARRARO.................................................................................................................. 28
2.1 SPECIFICATIONS ............................................................................................................................... 28
2.3 FAULT FINDING.................................................................................................................................. 81
3. SPECIAL TOOLS........................................................................................................................................ 84
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1.
REAR AXLE 2WS
1.1
The rear axle is a rigid axle and is fixed by 4 screws

to the chassis with a torque value of 800 Nm.
It incorporates the following features:
Z mechanically operated differential unit;
Z hydraulically operated oil immersed foot brakes fitted with four disc brakes;
Z planetary gear carrier with 3 gears.
Power from the transmission output shaft is transmitted to the rear axle through the flange (1), the
brake pads (2) and the half shaft (3) to the rear fire.
The pinion is located on preloaded bevel roller bearings.
The differential is located on two roller bearings, the
right hand bearing supported by an internal web of
the axle centre housing.
The crown is fixed to the differential housing. Drive
from the housing is transmitted through a four pinion
differential to sun gear shafts which are splined into
the differential side gears.
The differential lock sliding coupling is located on the
splines of the right hand differential side gear. The
coupling has dog teeth which engage with the dog
teeth on the differential housing lock adaptor.
If the dog teeth are not aligned, the spring engagement link will be preloaded, ensuring rapid and full
tooth engagement when the dog teeth align.
The differential lock will remain engaged due to dog
tooth side loading as long as the rear wheels have
unequal traction.
The return spring disengages the lock when both
wheels have equal traction or drive is disengaged.
The brakes are mounted on the final reduction sun
gears. These brakes are wet disc type with hydraulic
piston actuator operated by foot pedals, independently for turning assistance, or together for transport.
The gears (4) are mounted in a carrier and are positioned around the sun gear and within the ring gear
(5). The rear axle shafts (3) are located into the internal splines in the carriers.
As the sun gear is driven by the differential, the gears
revolve inside the stationary planetary ring gear and
drive the carrier and axle shaft at reduced speed.
The rear axle shaft is supported on taper roller bearings (6). Preload is adjusted by means of selective
shims held under the retaining plate and screws.
4
F29546
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ELECTRICAL DIFFERENTIAL LOCKING

OPERATION (Powershift)
SWARNING
The differential lock fitted to this machine is operated
by oil pressure and controlled by an electrically operated solenoid. The solenoid valve is energized by
means of the button (1) mounted in the right control
lever.
The differential lock effectively places both rear
wheels into a direct drive when selected, this action
stops one rear wheel spinning.
In conditions inducing wheel slip (differential lock not
yet engaged), press down the differential lock switch
and the lock will engage giving direct drive to both
rear wheels.
The lock will remain engaged until either of the foot
brakes are applied and the machine stops or by disengaging the switch. The warning lamp on the instrument panel will turn off when the differential lock
has disengaged.
When selecting switch (1) on gauge cluster, the differential is activated with the oil pressure supplied by
the transmission, which acts on piston (3) for differential locking.
This oil under a pressure of 13-14 bar, always available when the engine is running, is controlled by a
solenoid valve. When the switch is released (differential locking not necessary) oil is diverted to the filler of the level dipstick (discharged) and the piston
spring (2) of the differential releases the locking (4).
F29548
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MECHANICAL DIFFERENTIAL LOCKING

OPERATION (Powershuttle)
SWARNING
Never use the differential lock at speeds above 8
km/h or when turning the machine. When engaged,
the differential lock prevents the machine from turning: this could cause accidents.
In conditions inducing wheel slip, hold down the differential lock pedal (1) with your heel until the lock is
felt to engage. The lock will automatically disengage
when traction at the rear wheels equalizes. If a rear
wheel spins at speed, reduce the engine speed to
idle before engaging the differential lock to minimize
shock loads on the rear axle.
When pedal (1) is pressed, a system of levers activates outer lever (2) that on its turn acts on bracket
(3) locking the differential. By releasing pedal (1) the
lever is also released and the differential is unlocked.
2
3
F29549
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1.2

SPECIFICATIONS
F29550
POWERSHIFT
POWERSHUTTLE
RATIO
4.62:1
4.11:1
LUBRICATION
Oil capacity: 21.2 litres
Oil specification: Akcela Hy-Tran Ultra MAT3525 + AoA Axle oil additive (0.8 litres)
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11
10
1
5
8
6
7
F29551
1.
2.
3.
4.
5.
6.
Screw of half shaft: 554626 Nm

Screw of axle assy - rear RH or LH: 190231 Nm
Screw of front flange: 136170 Nm
Screw to fixed rear axle to the chassis: 800 Nm
Screw: 1114 Nm
Screw of block: 5776 Nm
7.
8.
9.
10.
11.
Screw of baffle oil: 4351 Nm

Plug: 2734 Nm
Screw: 3241 Nm
Screw of housing rear brake: 204245 Nm
Right nut: 406 Nm
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1.3
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REAR AXLE REMOVAL

For servicing of any rear axle component the axle
must be removed.
Prior to removal of the axle place a suitable clean
container under the axle, capable of holding 21.2 litres and drain the oil from the plug at the base of the
axle.
Disconnect the differential lock lever.
Gain access from the top of the rear axle, disconnect
and drain the residual brake oil into a suitable clean
container. Remove the pipes from both sides of the
axle half shafts. Plug the brake pipes to prevent any
dirt or contamination entering the brake system.
Remove the 4 attaching screws from the drive shaft
coupling and remove from the axle.
Before removal of the axle make sure the machine is
on level ground with the loader fully lowered and
backhoe resting on the ground. The stabilizers must
be lowered to the ground and the front wheels
chocked.
Support the axle and remove the retaining screws,
gently lower the axle to the ground.
Place the axle on a suitable stand to facilitate the repairs.
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DIFFERENTIAL REMOVAL
Unscrew the upper screw (1). Use the hole of this
screw and holes (A) to install tool 380000990 for the
lifting of half-beam housing (2).
Unscrew and remove the remaining screws (1).
1
A
Remove the left housing of the half-beam (2) with

the differential (3) using the tool 380000990, from
the axle central body (4).
At this point it is possible to remove from the left

housing of the half-beam the differential group assy.
The differential consists of:
Z differential lock spring (5);
Z differential housing (6);
Z crown wheel (7).
F29552
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DIFFERENTIAL DISASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
Safety ring
Washer
Dog gear
Spring
Dog
Differential half housing
Crown wheel
Screw
Prior to separating the differential, mark the two half

housings (6) and (15) to ensure correct reassembly.
Replace the differential lock coupling and adaptor if
worn or damaged.
9.
10.
11.
12.
13.
14.
15.
16.
Bearing
Thrust washer
Side gear
Spider assembly
Side gear
Thrust washer
Differential half housing
Bearing screw
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The differential lock can be disassembled by compressing the spring and carefully detaching the snap
ring (1).
With the snap ring removed disassemble the: washer (2), outer dog (3), spring (4), inner dog (5) from
the housing (6).
Carefully inspect all moving parts for signs of scoring, wear, or damage, if evident replace with new
parts.
By means of an extractor remove the bearing (16).
Loosen and remove the screws (17). Disassemble

the half-housing of differential (15).
Now it is possible to remove the thrust washers (10)

and (14), the gears (11) and (13) and the spider
gears (12).
11
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PINION REMOVAL
1.
2.
3.
4.
5.
6.
7.
8.
Ring nut
Lock pin
Washer
Seal
Coupling
Bearing
Spacer
Flange
Remove the lock pin (2) to unlock the ring nut (1).
9.
10.
11.
12.
13.
14.
15.
Disc
Seal
Bearing
Pinion
Bearing
Safety ring
Screw
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Using the special tool 380002675 hold the coupling

(5) steady while loosening the ring nut (1).
Remove the ring nut (1), the washer (3) and the gasket (4).
Remove the coupling (5).
Loosen and remove the screws (15).

Remove flange (8).
Remove the bearing (6) from the flange (8).
13
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Remove the snap ring (14) from the axle inner central body.
Using an rubber hammer, take out the pinion (12).
12
14
F29553
Remove from the pinion (12), the spacer (7) and by

means of extractors, the bearings (11) and (13).
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15
BRAKE GROUP DISASSEMBLY

Powershuttle
10
11
17
14
12
13
15
16
RH
LH
F29554
Powershift
18
16
15
20
19
13
12
RH
LH
F29555
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Housing brake outer

O-ring
O-ring
Piston brake
Disc brake intermediate
Disc brake
Housing brake inner
Baffle oil (powershuttle)
Screw
Shim
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Block (powershuttle)
Washer
Screw
Screw
Housing brake inner
Housing brake outer
Screw
Baffle oil (powershift)
Block (powershift)
Screw
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Unscrew and remove the screws (17) then disassemble the block (11) with the shims (10).
10
11
17
12
13
8
F29556
Loosen and remove the screws (9). Remove the

housing brake inner (7).
Remove the brake pads (6) and the intermediate

disks (5).
F29557
Remove the brake piston (4) and the outer housing

brake (1).
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AXLE SHAFT ASSY RIGHT AND LEFT DISASSEMBLY
1.
2.
3.
4.
5.
6.
7.
8.
Sun gear
Retainer
Screw
Washer
Shim
Gear carrier
Bearing
Manifold brake tube
The brake manifold (8) can be removed by loosening and removal of the screws (9). Before reassembly fit a new O-ring (11). On reassembly torque the
attaching screws to 11 - 14 Nm.
9.
10.
11.
12.
13.
14.
15.
16.
Screw
Screw bleeder
O-ring
Axle housing assy right or left
Bearing
Seal
Shaft with wheel hub
Ring gear
17
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To remove the gear carrier assy (6) from the support

(16), remove the retainer (2), the retaining screws
(3), the washer (4) and the shim (5).
Remove the gear carrier assy (6).
If necessary, it is possible to disassemble the gear

carrier assy:
Z Remove the retaining ring (A).
Z Extract the gear pins (B) and remove the gears (C).
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The ring gear (16) can be removed from the axle

(12) with the aid of tool 380000816. Position the tool
beneath the ring gear, expand the plates and tighten
the screws. Invert the axle and press out the gear
from the wheel hub side.
Inspect the gear for wear, scoring or damage and
repair or replace.
Position the axle housing (12) to allow removal of

the shaft with wheel hub (15).
Using the puller tool 380000986 and the slide hammer 380000987, remove the bearing cups (13) from
the axle housing (12).
By means of extractor 380002676 remove the bearing (13) from the axle shaft (15).
Applying gradual pressure to the tool, the bearing
will separate from the half axle.
Inspect the bearing for wear, scoring or damage and
replace if in any doubt.
19
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Reassembly of the bearing is the reverse procedure. Using an induction heater, heat the bearing
sufficiently to expand it enough to allow it to easily
seat onto the half shaft.
IMPORTANT:
After bearing removal, disassemble the seal (14)

from the shaft with wheel hub (15).
NOTE: always fit a new axle seal if the axle bearing
is removed for any reason.
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21
MEASUREMENTS AND ADJUSTMENTS

PRELOAD OF PINION BEARING
The pinion bearing preload is set by selecting the

correct shim (spacer) which is placed between the
bearings.
Reassemble the pinion assembly, attach the fabricated spanner 380002675 to the flange (1) and
torque to 406 Nm with spanner to the locknut (2).
MEASURING OF PINION ROLLING TORQUE

Use a torque metre (1) to check rolling resistance
when the assembly is fitted back into the axle.
The rolling resistance should be: 1.3 Nm. Leave pinion retainer screws loose for this check.
If under specification, fit a smaller shim. If over specification, fit a larger shim.
AXLE SHAFT BEARING PRELOAD

The preload of the axle shaft bearing is realized by
placing the shims (1) between axle shaft (2) and
washer (3) as many as necessary to achieve value
X.
3
F29558
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22
The procedure to determine value X occurs in the

following manner:
Z install the largest shim (for instance 2.286 mm);
Z position the gear assy;
Z screw and tighten screw at 554626 Nm;
Z by means of a dial gauge, find out the axle backlash (for instance 0.562 mm);
Z subtract endfloat from shim already fitted, for example 2.286 - 0.562 mm = 1.724 mm.
The Resultant value is obtained.
Z starting from the Resultant value, refer to the table for the correct shim to replace the 2.286 one.
IMPORTANT: increasing shim thickness will reduce
preload. Decreasing shim thickness will increase
preload.
Z fit selected shim and re-tighten retained screw to
correct torque and allow lock plate to locate.
RESULTANT VALUE
SHIM TO BE INSTALLED
1.245 - 1.270 mm
81803491
1.346 - 1.372 mm
81803502
1.448 - 1.473 mm
81803503
1.549 - 1.575 mm
81803504
1.651 - 1.676 mm
81803505
1.753 - 1.778 mm
81803506
1.854 - 1.880 mm
81803507
1.956 - 1.981 mm
81803508
2.057 - 2.083 mm
81803509
2.159 - 2.184 mm
81803510
2.261 - 2.286 mm
81803511
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MEASURING OF AXLE SHAFT ROLLING TORQUE

After fitting the correct shim to set the preload: manufacture a bridging bar to span opposing screw
holes to the dimensions shown.
Fit bridging bar (1) across the rear axle housing

flange and use a torque metre (2) to check rolling resistance which should be 2.3 - 10 Nm.
NOTE: the brake housing, brake pads and sun gear
should not be installed but all bearings well lubricated.
If out of specification the shim should be adjusted
and rolling resistance rechecked.
23
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DIFFERENTIAL BEARING PRELOAD

This adjustment is made by shimming the right hand
differential bearing cone.
The value of following shimming is required: dimension T.
VALUE T
mm
SHIMS
0.034 0.039
81803515
0.040 0.045
81803516
0.046 0.051
81803517
0.052 0.057
81803518
0.058 0.063
81803519
0.064 0.069
81803520
0.070 0.075
81803521
0.076 0.081
81803522
Remove the differential bearing cone and shim from

the outer brake housing.
Place the gauge ring of tool 380000991 (1) into the
vacant bearing location.
Screw bridge tool 380000991 (1) across the rear
axle housing flange with spacers (2) located between the axle housing flange and the tool.
Measure the gap between the bridge tool and the
gauge ring using a feeler gauge (3).
Refer to the table to determine the correct size shim
which should be installed between the brake housing and bearing cone, thus preloading the bearing
back to specifications.
F29559
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25
MEASURING OF RANGE BETWEEN THE FACE THRUST BLOCK AND THE BACK FACE OF
DIFFERENTIAL
For dimensions S outside normal gap range use
as required the minimum number of shims to provide design gap of 0.10 - 0.20 mm.
VALUE S
mm
SHIMS
0.80 0.89
87346232 + 87346228
0.90 0.99
87346232 + 87346231
1.00 1.10
87346232 + 87346427
F29560
This procedure has the goal to get a clearance of

0.10 mm to 0.20 mm between the thrust face of the
thrust block and the back face of the differential bevel gear.
To get this setting we perform two measurements to
calculate the shim pack to be used.
Z On the centre housing, with the differential assy installed and centered, we check the distance from
the back of the bevel gear to the trumpet mounting
face of the centre housing. During this measurement rotation of the differential is needed to get the
shortest reading. This is to take the run-out of the
back face in calculation thus to avoid interference
afterwards (dimension Y).
Y: dimension from back of differential bevel gear to
trumpet mounting face.
F29637
A: gauge clamped on housing and differential

aligned to check the dimension Y.
F29638
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Z Assemble the thrust block to the trumpet housing

(NO SHIMS mounted in between the parts!).
Check the distance from the thrust face of the
thrust block (1) to the centre housing mounting
face of the trumpet housing (2) (dimension X).
F29639
B: gauge on trumpet housing.
F29640
S= Y-X will give you the minimum gap between the

thrust block and the back of the differential bevel
gear. Based on this calculation and the attached
shimming chart people find the shims to be used.
Shim pack thickness to be checked prior installation.
Disassemble the thrust block, fit the shim pack in
between the thrust block and the trumpet housing
and reassemble thrust block again.
Check free rotation of axle input on the completed
axle sub-group.
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1.4
27
FAULT FINDING
PROBLEM
Differential lock not engaging

(mechanical differential lock)
Differential lock not disengaged

(mechanical differential lock)
Differential lock not engaging

(electrical differential lock)
CAUSE
CORRECTION
External linkage damaged or

broken
Replace/repair as required.
Internal linkage, cross shaft rod,

fork or pivot shaft damaged/
broken
Remove and inspect.
Damaged or broken teeth on

differential lock adaptor or
coupling
Remove differential and inspect

differential lock assembly.
Spring broken between adaptor

and coupling
Remove differential and replace

spring.
Teeth of adaptor or coupling

damaged/burred

damaged parts.

broken
Remove, inspect and repair.

coupling

Solenoid valve sticking not

operating
Solenoid valve electrical
connection poor or coil not
energizing
Differential lock not disengaged
(electrical differential lock)
Spring broken between adaptor

and coupling

spring.
Teeth of adaptor or coupling

damaged/burred

damaged parts.

broken
Remove and inspect.

coupling

Solenoid valve electrical

connection poor or coil not
energizing
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28
2.
REAR AXLE 4WS CARRARO
2.1
SPECIFICATIONS
Rear steering axle, model 26.32M
POWERSHIFT
SELF LOCKING
RATIO
19,038
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29

Differential oil capacity
11 litres
Reduction gear oil capacity, on each side
1.3 litres
Oil specification:
manufacturer
DESCRIPTION
Akcela Nexplore MAT3525
POSITION
Level and fill plug for differential oil
Air breather
Differential oil drain plug
Greasing points
Brake bleed plug
Service brake oil inlet
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Before draining the oil, loosen the oil breather (2) to

release possible internal pressure, then tighten the
plug to the requested torque.
F28005
To drain the oil from the central body unscrew the

plug of the draining hole (4) and level hole (1).
Then tighten them to the specified torque.
F28006
Before draining the oil, position the wheel hub so

that the filler cap is in the highest point, then loosen
the plug (3) to release possible internal pressure.
F28007
Position the wheel hub so that the filler cap is on the

centre line of the horizontal axis.
Check oil level and top up if necessary.
Tighten the plug with a torque wrench to the prescribed torque.
F28008
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31
Before draining the oil, loosen the breather (6) to release possible internal pressure.
Check oil level and top up if necessary.
Tighten the plug with a torque wrench to the prescribed torque.
6
F28009
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32
2.2

FRONT FLANGE
7
6
5
4
3
F28010
Disassembly
Remove the snap ring (1).
F28011
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33
Remove the front flange (2).
F28012
Remove the seal ring (3), the O-ring (4), the gasket
(5), the O-ring (6) and the washer (7).
7
6
F29009
Assembly
Assemble the washer (7) and the new O-ring (6).
7
6
F29322
Assemble the gasket (5).
F29323
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Assemble the new O-ring (4) and the seal ring (3).
4
3
F29324
Assemble the front flange (2).
F28012
Assemble the snap ring (1).
F28011
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35
STEERING CYLINDER
10
11
12
2
1
6
13
14
16
15
17
18
19
20
21
22
23
24
F28013
Disassembly
(2).
SWARNING
3
2
1
F27228
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their conditions.
Unscrew the fastening screws (6) and (9) and take
the steering cylinder (7) out of its housing, if necessary use a rubber hammer.
or replaced.
10
11
12
13
F28014

16
18
20
17
21
19
22
23
24
F28015
Assembly
16
18
20
17
21
19
22
23
24
F28016
and (11), the nuts (4) and (12) to the ends of the rod,
then tighten with a dynamometric wrench to the requested torque.
10
11
12
3
13
F28017
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37

Assemble and tighten the screws (6) and (9) to the
specified torque.

Screw in the tie rod (13) so that its ball joint can be
inserted into the swivel housing arm (14).
12
13

14
Insert the ball joint of the tie rod (3) into its housing
in the swivel housing (2).
torque.
F28020
1
2
F27236
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38
REDUCTION GEAR
4
11
9
10
8
7
6
5
1
3
2
F27404
Disassembly
F27240
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39
co

1
F28044
Remove the planetary carrier cover (1) from the

wheel hub.
Position the planetary carrier cover (1) on a workbench and check its wear conditions.
F27405
To replace the gears, if necessary, remove the

screw (11) and the relevant washers (8) and (9).
NOTE: treat the pin (10) with care.
10
11
9
8
F28021
Remove the gear (7) from its seat, taking care not to
lose the rollers inside it.
Remove the shim (5).
7
5
F28022
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If the pins of the gears are in poor conditions, replace the entire planetary train with pre-fitted pins.
F28023
Assembly
Place the planetary carrier on a workbench and fit
the gears (7) and the relevant shims (5).
7
5
F28024
Insert all the rollers into the gears, then position the
two washers (8) and (9).
NOTE: the first washer must be aligned with the
dowel (10) pin.
9
10
F28025
Screw in and tighten the screws (11) to the specified

torque.
11
F28026
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41

wheel hub.
F27405

torque.
1
F28044

F27408
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WHEEL HUB
Disassembly
ring.
SWARNING
14
F27410
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43
F27250

7
5
F27251
To extract the ring gear carrier, screw in two of the

just removed screws (5) into the threaded holes.
Remove the ring gear carrier (7) with the ring gear
(4).
5
7
4
F27253

ring gear carrier using a hammer and the special
tool 380002667.
8
6
7
4
F27252
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15
11
F27254
12

Remove the bearing cone (12) from the swivel housing end using a suitable extractor.
13
11
10
9
F27412

SWARNING
17 19
16 18
14

F27256

14
F27257
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45
Collect the belleville washers (23) and (28).
28
23
F28046

NOTE: this is a destructive operation for the seal
ring.
22
Turn the swivel housing and take the bush (26) out,
14
23
F27259
Assembly
(20).
20
21
F27260
Force the bush (26) into the swivel housing (14) using the special tool 380002668 and a hammer.
14
26
22
F28047
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Grease well the king pin housings with specific

grease.
Position the belleville washers (23) and (29).
28
23
F28046
If previously removed, assemble the king pins (24)

and (27) onto the king pins (16) and (18).
24
27
18
16
F28027

ring.
14
F27257
17 19
16 18
F27263
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47
Position the wheel hub (11) on a workbench and assemble the bearing cups (9) and (12) in position with
the special tool 380002222 under a press or with a
hammer.
Assemble the seal ring (13) into the wheel hub (11)
12
11
Assemble the bearing (12) onto the swivel housing

end (14).
13
11
F28028
14
12
F27265

F27266

8
7
4
F27267
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F27268
Completely insert all bushes (6) using the special

tool 380002667 and a hammer.
Assemble the wheel carrier (7) fastening screws (5)
and tighten to the specified torque.
5
7
F27269
Assemble the washers (2) and (3) on the end of the

cardan shaft.
Insert the snap ring (1) on the end of the splined hub
and push it into its seat.
in its seat.
F27250
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49
CARDAN SHAFTS
F27279
Disassembly
F27280
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Remove the seal rings (2) from the axle beam (4).
3
2
Remove the bushing (3) from the axle shaft (4) only
if the wear conditions require it.
SWARNING
F27281
Assembly
Assemble the bush (3) on the axle beam with the
F28029
F28048
SWARNING
4
1
F28049
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51
AXLE BODY AND BRAKES
F28030
Disassembly
Put alignment marks on the axle beam body and on
the differential supporting flanges, in order to identify the right side and the left side with certainty.
F28031
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Position the axle on supports fitted to hold either the

central body or the axle-beam, even after their disjunction, or secure the three disjointed groups to a
lifting device with ropes or belts.
Unscrew the screws (2) to disassemble the axle
beam trumpet (1).
1
F28033
Remove the axle beam trumpet (1).
SWARNING
Once the axle beam trumpet has been removed, the
brake disks are free.
F28034
Remove the disks (9) and the intermediate disks

(10).
Remove the gear (8), the remaining brake disk and
the brake counterdisc (15).
15
10
9
8
F28035
Secure the brake flange (7) to a hoist with ropes or

safety belts.
Unscrew the upper screw (5) and the lower screw
(6). Remove the flange (7) from the central body, together with the bevel gear backlash-adjusting ring
nut.
SDANGER
This operation frees the differential box, that accidentally could fall.
7
F28036
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Remove the O-ring (4) and (19) from its housing and
from oil pipe hole and check its conditions.
53
19
F28037
Collect the brake flange (7) and place it on a workbench or fix it in a clamp.
Unscrew screws (11).
11
7
F27313
Take from the piston (14), the springs (13) and the
bushes (12) and (27) and spacer (26).
27
26
14
13
12
F28038
Unscrew the breather (21) from the brake flange (7).
21
F28039
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Copyright
Take the piston out (14).

If necessary, blow in air through the brake bleeder
vent to eject the piston, using the minimum pressure.
Remove the O-rings (16) and (17) from the piston
(14) and check their conditions.
16 17
14
F28040
Assembly
Assemble the O-rings (16) and (17) on the piston
(14) and lubricate the fraying surface piston/flange
with a light layer of grease.
16 17
14
F28040
Install the piston (14) into the brake flange (7) and
then a support flat disk on the piston and with a lever
anchored to an eyescrew, exert a pressure just
enough to insert the piston (14) into the brake flange
(7).
14
F28042
Collect the self-adjust kits components and insert

them in the piston (14).
Insert the fastening screws (11) and tighten them to
14
11
F28116
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Assemble the new O-rings (4) and (19).
55
19
F28037
Assemble and tighten the upper screw (5) and the

lower screw (6) fastening the brake flange (7) to the
specified torque.
F28043
Assemble the brake disks (9), the intermediate

brake disks (10), the gear (8) and the brake counterdisc (15).
15
10
9
8
F28035
Assemble the new O-ring (4).

In order to place the axle beam correctly, position
the half-beam (1) check the reference marks carried
out during disassembly.
4
1
NOTE: if new brake pads are installed, before assembling, they should be dipped in the required oil.
F28034
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Copyright
Assemble the axle-beam (1) on the flange, being

careful to the fastening holes alignment.
SWARNING
Support the groups properly as already pointed out
for disassembly phase.
Screw in and tighten the screws (2) of the axle shaft
drum to the specified torque.
1
F28033
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57
DIFFERENTIAL GROUP (STANDARD)
4
5
15
10
14
18
17
16
13
14
15
11
12
F28050
Disassembly
Loosen the screw (4) and remove the ring nut retainer (5).
Unscrew the ring nut with suitable special tool
320002218.
Remove the ring nut (6).
F28051
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Copyright
Remove the bearing cups (6).
F28052
Support the differential assy (2) with a rod and remove it.
F28053
18
F28054
F28055
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59
Loosen all screws (1) of the ring gear (10).
10
SWARNING
F28056
10
F28057

F28058
17
16
F28059
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Remove the shaft (13), the gears (14) and the

spherical washers (15).
15
15
14
14
13
F28060
12
11
F28061
Assembly
SWARNING
F28079

14
12
16
14
F28063
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61
16
17
F28064
15
15
14
14
13
F28060
11
12
F28066

unit (8) and (9).
SWARNING

F28058
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Copyright
10
F28067
1
F27316
1
F27315
18
F28068
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63
F28069
Support the differential assy (2) with a rod and assemble it.
F28070
Fit the outer cups of the bearings (7) by means of

F28071
Insert and tighten the ring nuts (6), using the wrench
380002218 until the clearance of the bearings is removed.
NOTE: tighten the ring nuts gradually but not excessively.

Assemble the ring nut retainer (5) and fasten it by
means of the screw (4).
5
F28072
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64
DIFFERENTIAL GROUP (SELF-LOCKING)
4
5
6
15
16
10
17
17
16
11
15
18
12
13
19
16
15
15
13
11
16
14
12
F28073
Disassembly
Loosen the screw (4) and remove the ring nut retainer (5).
Unscrew the ring nut with suitable special tool
380002218.
Remove the ring nut (6).
F28051
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65
Remove the bearing cups (6) with a hammer.
F28052
Support the differential assy (2) with a rod and remove it.
F28053
18
F28054
F28055
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Copyright
Loosen all screws (1) of the ring gear (10).
10
SWARNING
F28056
10
F28057

F28058
11
12
F28074
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67
19
13
F28075
Remove the shaft (17), the gears (16) and the

spherical washers (15).
15
15
16
16
17
F28076
14
13
F28077
11
12
F28078
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Copyright
Assembly
SWARNING
F28079

16
14
19
16
F28080
11
12
F28078
13
14
F28077
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69
15
15
16
16
17
F28082
19
13
F28081
11
12
F28074

unit (8) and (9).
SWARNING

F28058
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Copyright
10
F28067
1
F27316
1
F27315
18
F28068
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71
F28069
Support the differential assy (2) with a rod and assemble it.
F28070
Fit the outer cups of the bearings (7) by means of

F28071
Insert and tighten the ring nuts (6), using the wrench
380002218 until the clearance of the bearings is removed.
NOTE: tighten the ring nuts gradually but not excessively.

Assemble the ring nut retainer (5) and fasten it by
means of the screw (4).
5
F28072
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Copyright
PINION GROUP
1
2
3
4
5
F28083
Disassembly
In order to prevent serious damage to the pinion
thread, unscrew the ring nut (9) with the special tool
380000406.
F29645
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73
Once the ring nut washer has been removed, extract the pinion (1) from its housing by hitting it with
a hammer made of soft material on the splined end.
F28085
Remove the washer (6), the spacer (5) and the

shims (4) from the pinion (1).
1
4
5
6
Remove the bearing (3) from the pinion (1) using an

extractor.
Remove the shim (2) located under the bearing and
check its wear conditions.
F28086
F28087
Remove the bearing cup (7) from the central body.
F28088
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Copyright
Remove the bearing cup (3) from the central body.
F28089
Assembly
Position the central body on a workbench.
Force the cups of the bearings on their housings using the special tool 380002215 for outer bearing
race and for inner bearing race.
F28090
In order to measure the distance, the kit composed

of the special tools, respectively called false pinion
380002673 and false differential box 380002674,
is used.
Insert the false pinion, together with its bearings and
its ring nut, in the just mounted housings for the
bearings.
Tighten without exceeding, till the backlash is eliminated.
F28091
Check the correct positioning of the right and left

flanges, using the reference marks on them and on
the central body.
Assemble the two brake flanges and fix them with
their screws (screw in at least two ones diametrically-opposed for each flange).
F28092
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75
Insert the false differential box 380002674 into the

central body to measure the distance.
Check that the false box is inserted in both brake
flanges housings.
C
A
B
Carry out the measurement with a depth gauge

through the suitable false pinion hole.
X = (conical distance to be measured)
A = (measured value)
B= (known value)= 100 mm
C= (known value)= 50 mm
(A+C) - B = X
F28093
F28094
In order to determine the shim (S) necessary between the pinion and the bearing, you should subtract the (V) value stamped on the pinion head (V =
requested conical distance) from the (X) value.
S = X-V
F27331
Remove the false pinion, the bearings and the ring

nut from the central body.
Disassemble the false differential box from the
flanges and then unscrew the screws to remove the
flanges.
F28095
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Copyright
Insert the shim (2) on the pinion (1) with the chamfer
against the gear.
Press the bearing (3) into the pinion, making sure
that it is well set.
1
F28096
Insert the shims (4) and (6) and the spacer (5) into
the pinion (1).
1
4
5
6
F28086
Insert the pinion (1) into its seat in the central body
housing and the bearing (7) into the pinion end.
F28097
Insert a new washer (8) and a new ring nut (9).

Screw the ring nut in, using the wrench 380000406
for ring nut and for pinion retainer.
SWARNING
The torque setting is given by the preloading measurement on bearings.
F28084
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77
Carry out the preloading measurement (P) of the

pinion taper roller bearings, using a dynamometer
380002672.
Once you got the requested preloading value, caulk
the ring nut.
F28098
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78
TOE-IN/STEERING ANGLE ADJUSTMENT
F28099
Toe-in
Put two equal one-metre-long linear bars on the
wheel sides and lock them with two nuts on the
wheel hub stud bolt.
SWARNING
bars.
500 mm
500 mm
F27340
Measure the distance in mm (M) between the bars

measurement point.
F27341
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79
diameter
nominal toe-in= A-2 measured toe-in= M-5
A -02
A
M -05
F27342

3
3
F27343

rods (1) to the specified torque.
F27344
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Steering angle
steering.
F27345
F27346

off the stop screw (4), locking it with the locknut (5)
to the prescribed tightening torque.
F27347

the same operations.
F27348
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2.3
81
FAULT FINDING
PROBLEMS
CAUSE
10 11

shaft breakage
while its turning
steering
Uneven wear of tyre
Friction noise
noise
tyres.
5. Bent half shaft
components.
Vehicles with wide steering angle may proceed with kicks, have steering difficulty or cause pneumatic wearing
at sharp turns. Reduce the steering angle to minimum and decelerate when the vehicle begins to kick.
10. Incorrect adjustment of the bevel gear set: parts of the transmission worn out
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82
PROBLEM
CAUSE
CORRECTION

outer side

the one foreseen
Pinion nut loose

Load bump
(insufficient backlash)
Pinion nut loose

Contaminated oil
additives



temperatures
Low oil level
Contaminated oil

program.
Excessive use

Axle beam body bent
Vehicle overloaded
Vehicles accident
Load bump
Contaminated oil
Excessive use
Normal wear out
Pinion nut loose
Replace bearings.

seals

Seal lip damaged
Contaminated oil


flange spline
Exhaustive use
Pinion nut loose
Replace the flange.

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83

defined
Exhaustive use
Continuous overload
Crash load of differential

components
Check and/or replace other

differential components.

Excessive use


or scratched
Contaminated oil

right level.

bearing worn out
Excessive use
Contaminated oil
Replace bearing.
intervals.

overloaded
Replace.
Wheel support loose

Beam body bent
Replace.
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84
3.
SPECIAL TOOLS
P/N CNH
APPLICATION
2WS
4WS
380000406
Disassembly/Assembly of differential ring nuts
380000816
Planetary carrier disassembly
380000986 +
380000987
Disassembly bearing cups from the axle housing
380000990
Axle housing lifting
380000991
Bearings pre-load measurement
380002213
Assembly of seal ring of the swivel housing
380002215
Assembly of pinion bearing outer cup
380002218
Disassembly/Assembly of pinion ring nut
380002222
380002226
Assembly of bushing in the half-beam
380002667
Assembly of bushings in the crown retaining hub
380002668
380002669
380002670
Assembly of seal ring in the half-beam
380002671
Assembly of differential bearing cups
380002672
Preload measure of pinion bearing
380002673
Measurement of pinion shims
380002674
Measurement of pinion shims
380002675
Connection flange disassembly
380002676
Disassembly of wheel carrier hub shaft bearings
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580SR
580SR+
590SR
695SR

1. SPECIFICATIONS ........................................................................................................................................ 3
2. PARKING BRAKE......................................................................................................................................... 6
2.1 PARKING BRAKE ADJUSTMENT ........................................................................................................ 7
3. BRAKE CYLINDERS .................................................................................................................................... 8
4. OIL BRAKE TANK ...................................................................................................................................... 13
5. BLEEDING PROCEDURE.......................................................................................................................... 13
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1.
SPECIFICATIONS
2WS
BRAKES OPERATION
HYDRAULIC
Brakes
Wet disc, piston operated
Oil brake
Akcela LHM
Number discs (on side)
Brakes disc total friction area
1,440 cm2
4WS
BRAKES OPERATION
HYDRAULIC
Brakes
Wet disc, piston operated
Oil brake
Akcela LHM
Number discs (on side)
Brakes disc total friction area
1,440 cm2
The loader backhoe has two braking systems:

a parking brake with two free floating friction pads;
hydraulically operated inboard wet disc brakes in the
rear axle.
The parking brake, when engaged, locks the brake
disc on the rear of the transmission.
Operation of the foot brake, instead, pressurizes the
brake fluid in the master cylinders which feeds the
brake pistons in the axle housing. The brake pistons
then compress the brake friction discs and separation discs, which locks the axle shaft to the axle
housing.
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BRAKE SYSTEM LAYOUT (2WS)
1.
2.
3.
4.
Brake piston assembly

Brake discs
Brake tank
Pressure switch
5. Master cylinders
6. Parking brake
7. Axle shaft
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BRAKE SYSTEM LAYOUT (4WS)
1.
2.
3.
4.
Brake piston assembly

Brake discs
Brake tank
Pressure switch
5. Master cylinders
6. Parking brake
7. Axle shaft
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2.
PARKING BRAKE
The parking brake is fitted to all models and incorporates two free floating friction pads.
When operated the cam (1) forces the friction pads
against the disc (2), effecting a braking action on the
output shaft from the transmission, locking the drive
shaft to the rear and front axles.
19
20
19
18
2
1
17
15
14
12
21
16
13
11
10
F27750
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Screw - brake mounting

Assembly - caliper
Nut - brake mounting screw
Nut - adjustment
Nut - adjustment
Washer
Washer
Thrust washer
Lever
Boot
Cam
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Oil seal
Bearing
Retainer
Cam
Torque plate - front
Carrier and lining assembly
Torque plate - rear
Sleeve mounting
Adjuster screw
Spring
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2.1
PARKING BRAKE ADJUSTMENT
The parking brake is located on the transmission output shaft on the 4x4 transmission and on the rear
axle on the 4x2 transmission.
The 4x2 transmission parking brake is located on the
rear axle brake disc splined to the pinion shaft (1),
hydraulic oil filter (2), parking brake cable (3), parking brake caliper (4).
When refitting the caliper unit (2) insert the two

screws (1) through the caliper. It will be necessary to
apply Loctite 270 to the locknuts (3). Tighten the
screws while holding the locknuts. Once the screws
are tightened, torque the nuts to 150 Nm. Ensure that
the tubes can move.
Adjust the clearance between the brake pads and

disc to 0.5 mm using the nut and locknut (1).
Adjust the cable and lock the nut (1) to get 4-5 clicks
on the parking brake lever.
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Copyright
BRAKE CYLINDERS
Brake cylinders are accessible from the engine compartment.

The brake cylinders are linked by a balancing pipe
(12) situated below the cylinders to maintain equal oil
pressure between the two cylinders.
1.
2.
3.
4.
5.
6.
Fitting
Pressure switch
Fitting
Body
Primary spool
Bottom
7.
8.
9.
10.
11.
12.
Seal
Clevis
Seals
Secondary spool
Spring
Balancing pipe
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MASTER CYLINDER WITH BRAKES RELEASED
10
7
F29371
Trapped oil
Tank oil (no pressure)
1.
2.
3.
4.
5.
Oil to cylinder (right hand side)

Pressure switch
Secondary spool
Tank inlet
Primary spool
With the brakes released the brake lines are open to

the tank to allow the brakes to release. The cylinders
are also open to tank through the centre of the valve.
6.
7.
8.
9.
10.
Cylinder body
Cylinder body
Primary spool stop
Balancing pipe
Oil to cylinder (left hand side)
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10
CYLINDER WITH BRAKE PEDALS DEPRESSED
10
7
F29372
Pressurized brake oil

1.
2.
3.
4.
5.

Pressure switch
Secondary spool
Tank inlet
Primary spool
As the brake pedals are depressed initial movement

of the cylinder piston closes the centre port to isolate
the tank.
Further piston movement creates brake oil pressure
to apply the brakes. The pressure ports are both
open as the two seals on both cylinders have exposed the two ports, therefore allowing equal pressure in both cylinders.
6.
7.
8.
9.
10.
Cylinder body
Cylinder body
Primary spool stop
Balancing pipe
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11
CYLINDER WITH ONE BRAKE PEDAL DEPRESSED
10
7
F29373
Pressurized brake oil

1.
2.
3.
4.
5.

Pressure switch
Secondary spool
Tank inlet
Primary spool
When using one brake to assist turning, the brake

cylinder being applied operates only one brake. This
is achieved by the pressure port being blocked by
the two seals on the cylinder not being operated.
6.
7.
8.
9.
10.
Cylinder body
Cylinder body
Primary spool stop
Balancing pipe
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Discs and piston layout

1. Steel plates
2. Outer housing
3. Seals
4. Piston
5. Friction plates
6. Outer housing
Piston and seals

1. Piston
2. Fitting
3. Outer housing
The brakes are supplied oil from the brake pedal

tank and into the axle by tubes into each half axle
through the fitting (2) which is sealed to the piston by
two O-rings.
When the fitting (2) is removed ensure the O-rings

are replaced with new.
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4.
OIL BRAKE TANK
1. Oil brake tank

2. Low level switch
NOTE: to test the warning light system, press the low
level button on the tank cap. The lamp illuminated is
that of the parking brake, mounted on the right-hand
instrument console; it indicates that the parking
brake is disengaged.
5.
BLEEDING PROCEDURE
1. Oil brake tank is full (1)
2. Open left hand brake bleed valve (2)
3. Press repeatedly on both brake pedals (3) to

purge the system
4. Hold pedals down
5. Lock bleed valve (2)
6. Release pedals
7. Repeat steps 4-6
8. Repeat steps 2-6 on right hand brake
9. Test brakes repeat if necessary
NOTE: when the brake pedals are operated, both together, the electrical supply to the front wheel drive
switch is cut. In this way the clutch de-energizes thus
engaging the front wheel drive, providing four wheel
braking.
13
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NOTES:
Copyright
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Copyright
580SR
580SR+
590SR
695SR

1. HYDRAULIC DIAGRAMS ............................................................................................................................. 3
1.5 HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS .................................................... 11
2. HYDRAULIC PUMP.................................................................................................................................... 13
2.2 SPECIFICATIONS ............................................................................................................................... 13
2.3 LOAD SENSING VALVE ..................................................................................................................... 16
2.4 REMOVAL ........................................................................................................................................... 18
2.5 COMPONENTS ................................................................................................................................... 19
3. CONTROL VALVES ................................................................................................................................... 24
3.1 CONTROL VALVES REXROTH (MECHANICAL MODELS) ............................................................ 24
3.2 REXROTH CONTROL VALVES (PILOT MODELS) ......................................................................... 40
3.3 SOLENOID VALVE FOR PILOTING THE BACKHOE CONTROL VALVE (WITH HYDRAULIC
CONTROL) ..................................................................................................................................................... 49
3.4 RELIEF VALVES ................................................................................................................................. 52
3.5 ACCUMULATOR GLIDE RIDE PARKER.......................................................................................... 60
4. HYDRAULIC SWING SYSTEM .................................................................................................................. 63
4.2 HYDRAULIC OIL FLOW ...................................................................................................................... 64
5. HYDRAULIC CYLINDERS.......................................................................................................................... 66
5.1 LOADER ATTACHMENT BOOM CYLINDER ..................................................................................... 67
5.2 LOADER BUCKET CYLINDER ........................................................................................................... 72
5.3 4X1 LOADER BUCKET CYLINDER .................................................................................................... 76
5.4 BACKHOE BOOM CYLINDER ............................................................................................................ 79
5.5 BACKHOE ATTACHMENT DIPPER CYLINDER ................................................................................ 83
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5.6 BACKHOE BUCKET CYLINDER......................................................................................................... 87

5.7 TELESCOPIC CYLINDER ................................................................................................................... 91
5.8 4WS STABILIZER CYLINDER - CENTER PIVOT............................................................................... 95
5.9 STABILIZER CYLINDER - SIDESHIFT ............................................................................................... 99
5.10 SWING CYLINDER.......................................................................................................................... 103
5.11 BACKHOE ATTACHMENT SIDESHIFT CYLINDER - SIDESHIFT ................................................. 107
5.12 SPECIAL TOOLS............................................................................................................................. 108
6. HYDRAULIC CONTROL LEVERS............................................................................................................ 109
6.1 SPECIFICATIONS ............................................................................................................................. 109
6.4 CONTROL LEVER VALVE ................................................................................................................ 116
7. FAULT FINDING ....................................................................................................................................... 119
7.1 PRELIMINARY CHECKS................................................................................................................... 119
7.2 FAULT FINDING ................................................................................................................................ 120
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1.
HYDRAULIC DIAGRAMS
1.1
HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS
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4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.

Front axle
Steering control valve
4x1 bucket cylinders
Dipper cylinders
Boom cylinders
Ride control valve (optional)
Ride control accumulator (optional)
Loader attachment control valve
Hand hammer control valve (optional)
Backhoe hammer control valve (optional)
Hand hammer (optional)
Backhoe hammer (optional)
Hydraulic pump
Priority valve
Air filter
Hydraulic oil cooler
Diagnostic
Oil filter
Return filter
Backhoe attachment control valve
Dipper cylinder
Bucket cylinder
Swing cylinders
Bi-directional auxiliary
Boom cylinder
Backpressure valve
Telescopic cylinder
Stabilizer right cylinder
Stabilizer left cylinder
Check valve
Check valve (optional)
Backhoe attachment travel lock cylinders (sideshift)
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1.2
HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS
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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.

Front axle
Dipper cylinders
Boom cylinders
Hydraulic pump
Priority valve
Air filter
Diagnostic
Oil filter
Return filter
Dipper cylinder
Bucket cylinder
Swing cylinders
Boom cylinder
Backpressure valve
Telescopic cylinder
Check valve
Left-hand hydraulic control lever
Right-hand hydraulic control lever
Boom or dipper left hydraulic control lever
Hydraulic control lever left-swing
Boom or dipper right hydraulic control lever
Hydraulic control lever right-bucket
Backhoe attachment control valve pilot solenoid valve
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1.3
HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS
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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

Front axle
Dipper cylinders
Boom cylinders
Hydraulic pump
Priority valve
Air filter
Diagnostic
Oil filter
Return filter
Dipper cylinder
Bucket cylinder
Swing cylinders
Boom cylinder
Backpressure valve
Telescopic cylinder
Check valve
Rear axle
4WS steering control valve
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1.4
HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS
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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.

Front axle
Dipper cylinders
Boom cylinders
Hydraulic pump
Priority valve
Air filter
Diagnostic
Oil filter
Return filter
Dipper cylinder
Bucket cylinder
Swing cylinders
Boom cylinder
Backpressure valve
Telescopic cylinder
Check valve
Rear axle
Boom or dipper left hydraulic control lever
Backhoe attachment control valve solenoid valve
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1.5
HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS
11
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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.

Front axle
Dipper cylinders
Boom cylinders
Hydraulic pump
Priority valve
Air filter
Diagnostic
Oil filter
Return filter
Dipper cylinder
Bucket cylinder
Swing cylinders
Boom cylinder
Backpressure valve
Telescopic cylinder
Check valve
Rear axle
Boom or dipper hydraulic control lever
Backhoe attachment control valve solenoid valve
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2.
HYDRAULIC PUMP
2.1
13
There are two types of pumps:

Z for 97 HP engine;
Z for 110 HP engine.
The gear type hydraulic pump assembly is mounted
on the rear of the transmission and driven by a shaft
directly connected to the engine flywheel splined to
the torque converter housing.
The pump comprises of two pumping elements, the
front pump (1) rear pump (2) and load sensing steering flow divider control valve (3).
Oil is drawn through the common inlet port into both
pumping elements.
Front pump flow is directed to the loader and backhoe attachment control valves and to the sideshift
locking cylinders.
Rear pump flow passes through the flow divider
valve which maintains priority oil flow to the steering
system with remaining flow directed for operation of
stabilizers, loader and backhoe elements.
2.2
SPECIFICATIONS
PUMP (97 HP ENGINE)
1st PUMP
Direction of rotation (looking on drive shaft)
2nd PUMP
Clockwise (D)
Displacement
40.258 (cm3/rev)
Inlet pressure range for pump
35.427 (cm3/rev)
0.7 - 3 bar
Maximum continuous pressure
P1
260 bar
260 bar
Maximum intermittent pressure
P2
280 bar
280 bar
Maximum peak pressure
P3
300 bar
300 bar
Operating temperature
Speed
Viscosity range
-25 to -80 (C)

min P1
350 (min-1)
max P1
3000 (min-1)
recommended
12 to 100 mm 2/s (cSt)
permitted
max 750 mm 2/s (cSt)
Dp > 200 bar

bx = 75 - 10 mm
8 - Nas 1638
Contamination class
Dp < 200 bar
bx = 75 - 25 mm
Relief valve
19 / 17 /14 - ISO 4406

10 - Nas 1638
21 / 19 /16 - ISO 4406
177 3 bar
Stand by pressure load sensing valve
7 bar
Weight
30 kg
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14
PUMP (110 HP ENGINE)
1st PUMP
Direction of rotation (looking on drive shaft)
2nd PUMP
Clockwise (D)
Displacement
40.258 (cm3/rev)
Inlet pressure range for pump
35.427 (cm3/rev)
0.7 - 3 bar
Maximum continuous pressure
P1
260 bar
260 bar
Maximum intermittent pressure
P2
280 bar
280 bar
Maximum peak pressure
P3
300 bar
300 bar
Operating temperature
Speed
Viscosity range
Contamination class
Relief valve
-25 to -80 (C)

min P1
350 (min-1)
max P1
3000 (min-1)
recommended
12 to 100 mm 2/s (cSt)
permitted
max 750 mm 2/s (cSt)
Dp > 200 bar

bx = 75 - 10 mm
8 - Nas 1638
Dp < 200 bar

bx = 75 - 25 mm
19 / 17 /14 - ISO 4406

10 - Nas 1638
21 / 19 /16 - ISO 4406
177 3 bar
Stand by pressure load sensing valve
7 bar
Weight
30 kg
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HYDRAULIC DIAGRAM
15
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2.3
1.
2.
3.
4.
5.
6.
7.
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LOAD SENSING VALVE
Orifice
Rear systems (EF)
Filter
Spool
To steering priority flow (CF)
Orifice
Inlet port from rear pump (IN)
When the steering is in neutral the LS port is connected to the unload (through the steering) and the
steering inlet port (CF) is open.
8.
9.
10.
11.
12.
13.
14.
Steering relief valve

Relief valve adjuster
Poppet
Return to inlet pump port
Lock plug
Load sensing signal (LS)
Orifice
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1
2
3
4
5
6
F29457
Load sensing valve with pump running - Steering in neutral
1.
2.
3.
4.
Return to oil tank

Trapped oil
Pressure oil
Orifice
Rear systems (EF)
Filter
Spool
5. To steering priority flow (CF)

6. Orifice
7. Inlet port (from rear port)
The pressure on (CF) increases until the pressure value (stand-by pressure) is sufficient to move the spool
valve in a way to divert the flow toward (EF).
1
2
3
4
5
6
F29458
Load sensing valve with pump running - Steering working
1.
2.
3.
4.
Trapped oil
Return to oil tank
Orifice
Rear systems (EF)
Filter
Spool
During steering two actions are performed:

1. The fluid moves to the steering through (CF).
2. The (LS) signal is in communication to the steering.
5. To steering priority flow (CF)

6. Orifice
7. Inlet port (from rear port)
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2.4
Copyright
REMOVAL
1. Drain the oil tank into a container capable of

holding up to 75 litres.
2. Disconnect the parking brake cable and the

transmission-to-rear-axle drive shaft.
3. Disconnect and plug pump inlet and pressure

hoses.
Remove the pump flange mounting screws and
remove the pump.
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2.5
COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Screw
Spool
O-ring
Plug
Valve
Filter
Fitting
Spring seat
Spring
O-ring
Cover
Relief valve
O-ring
Poppet
Spring
Seat
Rear pump body
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Bushing
Gasket
Bushing
Elastic retainer
Bearing
Gear
Gear
Front pump body
Gasket
Gear
Flange
Ring seal
Ring seal
Circlip
Pressure seal
Gear
O-ring
Screw
19
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2.6
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DISASSEMBLY STEERING CONTROL VALVE

To aid reassembly draw an alignment line along the
total length of the pump assembly.
Remove the screws (1).
Remove the load sensing steering control valve (2).

Check and eventually replace the O-rings (35).
DISASSEMBLY STEERING CONTROL VALVE

Do not disassemble the steering system relief valve
(A) if the steering circuit relief valve pressure was to
specification when pressure testing the pump prior
to overhaul.
NOTE: if the steering system relief valve is disassembled then the valve must be reset as described
in the trouble shooting pressure and flow testing
chapter before the vehicle is recommissioned.
Wash all components in an approved degreasant
and inspect for the following.
Valve bore must be free from scoring and damage to
metering edges.
The spool (3) should slide freely in the bore and be
free of scoring and damage.
Ensure all orifices are clean.
The relief valve seat should be free from pitting and
damage. A small chamfer on the mouth of the bore
is permissible.
Examine the filter (7) which fit inside the unload and
relief valves. The filter must be replaced if contaminated.
Pressure and flow test the pump.
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DISASSEMBLE REAR PUMP

Remove the screws (36).
Remove the rear pump assembly (18).
IMPORTANT: prior to disassembly and to ensure

correct reassembly identify the position of each
bearing block in the pump body as described below.
Scribe an identifying letter A and B, C and D
on the pump housing and in the channel of each
bearing block.
NOTE: orientation of bearing block seals relative to
oil port.
If scribe is not available take care to keep bearing

blocks in pairs.
Disassemble the gears (24), the seals (33), the elastic retainers (22) and the bearings (23). Wash all
components in approved degreasant.
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Inspect the wear track cut by the gears in pump

body. The body can be reused if the track is bright
and polished and does not exceed 0.08 - 0.076 mm
in depth.
Examine bearing block faces for scoring and flatness paying particular attention to the face which
abuts the gears. Examine bearing block bushes for
scoring. Examine pump gears for scored or worn
side faces, journals and damaged teeth.
If pump block, gears or bearing blocks are worn and

require replacement the pump assembly must be replaced. Reassembly follows the disassembly procedure in reverse whilst observing the following:
Z Ensure all parts are perfectly clean and lubricate
bushes and gears with clean hydraulic fluid.
Z Replace all seals and O-rings.
Z Install bearing blocks into the same positions from
which they were removed using identification letters scribed during disassembly.
Z Ensure plastic back-up seals are correctly positioned in the rubber seal.
DISASSEMBLY FRONT PUMP

To remove from the pump assembly (26) from the
flange (29) its necessary to remove the snap ring
(32).
Remove and replace the seal rings (30) and (31).
Identify and note the position of each bearing block

to ensure correct reassembly.
Disassemble the gears (28) and (34), the seals (33),
the elastic retainers (22) and the bearings (23).
Wash all components in approved degreasant.
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Inspect the wear track cut by the gears in the inlet

side of the pump body. The body can be reused if
the track is bright and polished and does not exceed
0.15 mm in depth.
Examine bearing block faces for scoring.
Inspect PTFE coated bearings in body or flange for
wear. If bearings are worn the bronze backing will be
revealed.
Examine pump gears for scored or worn side faces,
journals and damaged teeth.
Examine flange seal contact area on driveshaft. If
pump block, gears, bearing blocks or drive shaft are
worn the pump assembly must be replaced.
Reassembly follows the disassembly procedure in
reverse whilst observing the following:
Z Ensure all parts are perfectly clean and lubricate
bushes and gears with clean hydraulic fluid.
Z Replace all seals and O-rings.
Z Install bearing blocks into the same positions from
which they were removed.
Z Ensure back-up seals are correctly positioned in
the seal.
Assemble the inner seal, (30), with the spring and

the lip facing the pump. Install the outer seal (31),
with the spring and the lip facing outwards and refit
the snap ring (32).
Coat seal rings with high melting point grease.
NOTE: ensure seal rings are fitted back to back.
NOTE: if the seal ring recess has been scored during seal removal, coat the outside diameter of the
seal ring with flexible gasket sealant to prevent leakage.
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3.
CONTROL VALVES
3.1
CONTROL VALVES REXROTH (MECHANICAL MODELS)
The hydraulic circuit is a load sensing flow sharing

system working in conjunction with a fixed displacement gear type hydraulic pump.
This system has the advantage that at any time the
distribution of flow to the services being operated is
in proportion to the openings of the control valve
spools.
The flow distribution to the backhoe and loader control valves is independent of the load and it is therefore possible to operate two or more spools
satisfactorily at the same time.
The principal components of the load sensing flow
sharing system are the pressure compensator
valves in each control valve section, together with
the load sense line which connects all the spool sections in both the loader and backhoe control valve
assemblies.
Because the hydraulic pump is a fixed displacement
gear type pump it should be noted that the load
sense line only connects the loader and backhoe
control valve assemblies and does not have any
connection to the hydraulic pump.
The hydraulic pump draws oil from the tank and flow
from the front pump is directed to the centre galleries of the loader and backhoe control valves assemblies.
The flow coming from the rear section of the pump
passes through the load sensing flow divider valve
mounted on the pump and sends the priority flow to
the steering system, while the remaining flow adds
to the flow from the front pump, directed to the loader and backhoe attachment systems.
The centre gallery of both the loader and backhoe
control valves are blocked by the end plate.
Pressure in the supply system is controlled by the
pump flow balancer valve in accordance with the
pressure in the load sensing line.
Consequently the higher the load sense pressure
the less flow is returned to tank with corresponding
increase in flow/pressure to the hydraulic circuits.
Maximum system pressure is limited by the load
sense pressure relief valve which relieves pressure
in the load sense line when it reaches 210 bar.
Because the pump flow balancer valve is influenced
by load sense pressure the valve diverts sufficient
flow back to tank to maintain the maximum system
pressure of 210 bar.

The loader control valve is mounted on the right
hand side of the machine adjacent to the pump.
The valve assembly consists of a maximum of three
spool operated sections and provides oil flow to the
loader boom, bucket and auxiliary services where
fitted.
The backhoe control valve is located at the rear of
the chassis.
The control valve consists of a maximum of seven
sections of spool control valves and provides the oil
flow for operating the lifting, the digging, the bucket,
the stabilizers, the swing and telescopic arm (optional).
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Hydraulic system oil

Steering system oil
Load sensing oil
Suction oil
Return to oil tank
1.
2.
3.
4.
5.
6.
7.
Hydraulic tank
Hydraulic pump
Power steering
Hand hammer control valve
Hand hammer
8.
9.
10.
11.
12.
13.
Backhoe hammer control valve

Backhoe hammer
Oil cooler
Return line distributor block
Filter
Oil cooler by-pass valve
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26
OIL FLOW OPERATION

All loader/backhoe circuits in neutral
Each control valve section within the backhoe or
loader control valve assemblies contains a spool,
two check valves and a load sensing pressure compensator.
A load sensing gallery connects the compensators in
each control valve section.
When all control valves are in neutral position, the
spools stop the oil flow in each system and the pressure of the load sensing line can bleed to the tank
through the relevant 1 litre/min return-to-tank port in
the inlet cover of the backhoe attachment control
valve.
Because there is no load sense pressure being applied to the rear face of the flow balancer valve, the
valve will move against the spring and off its seat
when pump pressure reaches 15 bar. Pump flow is
now diverted back to tank and the balancer valve
maintains a stand-by pressure of 15 bar while the circuits are in neutral.
1
2
6
F29287
Flow balancer valve operation - All spools in neutral

Pump stand-by pressure 15 bar
Return to oil tank
1. Load sense bleed orifice 1 l/min
2. Load sense limiter (system relief valve)
3. Return to tank
4.
5.
6.
7.
Load sense line

Pump flow balancer (unload) valve
Pump flow IN
To backhoe control valves
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27
F29288
Load sensing flow sharing - All spools in neutral
1.
2.
3.
4.
Pump pressure
Trapped oil
Return to oil tank
Load non-return check valve
Load sense line
Pressure compensator
Spool
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28
One hydraulic circuit operating

When a single hydraulic circuit is operated the spool
in the control valve section is moved allowing oil to
flow past the lands of the spool and apply pressure
to the metering element of the pressure compensating valve.
The metering element moves upwards to allow oil to
flow to the load check valve and at the same time
uncovers the drilling in the spool portion of the pressure compensator valve enabling operating pressure to be sensed in the load sense gallery.
As pressure increases to open the load check valve,
load sense pressure is applied to the spring side of
the flow balancer valve in the backhoe control valve
end cover. A higher pressure is now required to op-
erate the flow balancer valve and pump pressure increase accordingly.
When pump pressure overcomes the pressure behind the load check valve, the valve opens allowing
oil to flow into the cylinder port.
Exhaust oil from the cylinder returns to tank through
the other port in the control valve section.
If pressure in a load sensing system reaches 195
bar, the safety valve in the side cover of the backhoe
attachment control valve will operate. Pump pressure is now limited to 210 bar. This is the pressure
required to overcome the pressure of the flow balancing valve spring (15 bar) plus the load sensing
pressure controlled at 195 bar.
1
2
6
F29289
Flow balancer valve operation - Hydraulic circuits operating

Pump pressure
Load sense pressure
Return to oil tank
3. Return to oil tank
4.
5.
6.
7.
Load sense line

Pump flow IN
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29
F29290
Load sensing flow sharing - One spool operating

Pump pressure
Trapped oil
Return to oil tank
1. Load non-return check valve
2. Load sense line
3. Pressure compensator
4. Spool
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30
Two or more hydraulic circuits operating

When two or more hydraulic systems operate, each
system will operate at a different pressure.
If pump flow to a specific system is not controlled,
the system requiring a lower operating pressure will
work faster than the system requiring a higher pressure, because the flow will have to overcome less
resistance.
To prevent this situation, the pressure compensating valve regulates the oil flow directed to the system operating at a lower load.
When two spools are operated simultaneously
pump pressure is applied to the metering element of
the pressure compensating valve in both valve sections.
Both metering elements therefore move upwards allowing oil to flow to the load check valves. At the
same time the aperture in the spool portion of the
pressure compensating valve is uncovered to allow
operating pressure to be sensed in the load sensing

gallery.
Pump pressure will rise until it exceeds the pressure
of the check valve of the system operating at the
heaviest load and the pressure in the load sensing
line has a value similar to that of the high pressure.
The pressure required to operate the system with a
lower load is now too high and, if not limited, it will
result in this system operating instead of and faster
than the system with a higher load.
To compensate for this condition, the load sensing
pressure moves the metering element of the pressure compensating valve in the system with a lower
load downwards and restricts the flow to the system.
This balancing of flow and pressure according to the
load ensures that both systems operate simultaneously and at a balanced flow rate.
1
2
6
F29291
Load sense relief valve operating

Pump pressure at 210 bar
Load sense pressure at 195 bar
Return to oil tank
3. Return to oil tank
4.
5.
6.
7.
Load sense line

Pump flow IN
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31
F29292
Load sensing flow sharing - Two spools operating

st
1 spool operating pressure

2st spool operating pressure
Trapped oil
Return to oil tank
1. Load non-return check valve
2. Load sense line
4. Spool
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LOADER CONTROL VALVE

The loader control valve is mounted on the right side
of the machine adjacent to the pump. The valve assembly consists of two or three spool operated sections:
Z Loader lifting
Z Loader bucket
Z 4x1 loader bucket
Usually the loader control valve has three valve sections when is installed on the loader backhoe the 4x1
bucket.
A.
B.
C.
1.
2.
3.
4.
5.
6.
7.
4x1 loader bucket section

Loader bucket section
Lifting section
End cover
4x1 loader bucket relief valve
Loader bucket relief valve (rod end) 240 bar
Hydraulic speed relief valve 165 bar
Hydraulic speed solenoid
Inlet section
Loader bucket relief valve (piston end) 165 bar
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Removal
Z Lower the loader to the ground, with the bucket
firmly placed on the ground.
Z Stop the engine and relieve any residual pressure
in the backhoe and loader attachment systems by
moving the relevant control levers through all operating positions.
Z Disconnect the battery.
Z Clean the area around the control valve.
Z Identify and disconnect linkage, cables and each
hose connection to the control valve and plug the
hose ends. A drip tray will be required to catch oil
draining from inside the hoses.
Z Unscrew and remove clamping screws to chassis.
Z Remove the valve assembly from the machine.
Z Installation is the reverse of the removal procedure.
Disassembly
Unscrew and remove the three nuts (1). Tightening
torque 27 2 Nm. Slide out the three tie bars (2).
Disassemble the end cover (4), the section control

valve (4), (5) and (6), and the inlet section (7).
Check and possibly replace the O-rings (8) located
between the section control valves.
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REAR CONTROL VALVE (WITH MECHANICAL CONTROL)

The rear control valve is located in the rear part of the
loader backhoe. It consists of six or seven valve sections together with an inlet and outlet end cover.
Valve sections are:
Z Right-hand stabilizer
Z Stabilizer left
Z Lifting
Z Crowd
Z Swing
Z Bucket
Z Telescopic (optional)
K. Hydraulic diagram for center pivot models

(4WS)
W. Hydraulic diagram for sideshift models
A. Right stabilizer section
B. Left stabilizer section
C. Dipper section
D. Bucket section
E. Swing section
F. Lifting section
G. Telescopic dipper section
H. Backhoe attachment travel lock valve (sideshift)
1. End cover
2. Inlet section
3. Dipper circuit relief valve (piston end) - 240 bar
4. Backhoe bucket circuit relief valve (piston end) 220 bar

5. Swing circuit relief valve (piston end) - 205 bar
6. Boom system relief valve (piston end) - 315 bar
7. Pump flow balancer - 15 bar
8. Load sensing return to tank
9. Swing circuit relief valve (rod end) - 205 bar
10. Boom relief valve (rod end) - 240 bar
11. Telescopic relief valve (rod end) - 205 bar
12. Load sensing relief valve - 210 bar
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Removal
Z Position the loader backhoe on a hard level surface.
Z Lower the loader attachment to the ground.
Z Lower the stabilizers.
Z Position the dipper in the vertical position, with the
bucket firmly placed on the ground.
Z Clean the area around the control valve.
Z Tag and identify the position of all hoses.
Z Disconnect and plug all the hoses.
Z Disconnect the levers of the manual control.
Z Unscrew and remove clamping screws to chassis.
Z Remove the valve assembly from the loader backhoe.
Z Installation is removal procedure in reverse.
Disassembly
Unscrew and remove the three nuts (1), tightening
torque 27 2 Nm.
Slide out the three tie bars (2).
Disassemble the end cover (3), the sections control

valves (4), (5), (6), (7), (8), (9) and (10), the inlet section (11).
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Disassembly the inlet section.

Remove the pump flow balancer valve (13), the load
sensing relief valve (14) and the check valve (15)
from the inlet section (11).
Disassembly the outlet section.

(Sideshift version)
Unscrew the knob (16).
Remove the solenoid (17) and the 2 way valve (18).
Disassembly the shuttle valve (19).
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37
Disassembly of control valve sections (with mechanical control)

There are indicated all possible solutions relevant to
backhoe control sections with mechanical control.
1.
2.
3.
4.
5.
Secondary relief valve

Pressure compensator
Check valves
Plug
Spool with spring return system
6. Spool with mechanical detent system (loader

boom element)
7. Spool with electrical detent system (loader
bucket element)
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Disassembly and reassembly mechanical control spool

Disassembly
Z Remove the screws (A), the boot along with its
plate (B) and the plate (C).
Z Remove the mounting screws (D) and the cover
(E).
Z Remove the spool (F) from the valve section.
Z Remove the lip seal (L).
Z Use a spool clamp (G) and a vice to secure the

spool.
Z Heat the spool to 200 C in an oven or with a heat
gun.
Z Remove the adapter (H), the retainers (I), the
spring (J), the plate (K) and the lip seal (L).
Z Remove the tongue (M) if necessary.
Reassembly
Z Reassemble parts in reverse order after greasing
the spring.
Z Position the metal part of the lip seal (L) on the outside of the spool.
Z The lip seal must be fitted on the end of the spool
so that it is not damaged by the spool grooves (N)
and its tightness is not damaged.
Z Slide the lip seal perpendicularly onto the spool.
Z Tighten the screws (A and D), the adapter (H) and
the tongue (M) from 9 to 11 Nm.
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Precautions to be taken for replacing the spool lip

seal.
Z Place the spool in the working section.
Z Slide the lip seal perpendicularly onto the spool,
positioning the metal part of the lip seal on the outside of the spool.
SWARNING
The lip seal must be fitted on the end of the spool so
that it is not damaged by the spool grooves (N) and
its tightness is not damaged.
Mechanical detent system spool

Disassembly
Z Remove the tongue and the cover sides.
Z Use a spool clamp (G) and a vice to secure the
spool.
Z Using a metal rod (minimum length = 80 mm, diameter 6) push the central ball (H) while extracting the
detent bush (I).
Z Mark the orientation of the detent bush for the reassembly.
Z Remove the balls (J) and the spring (K) from the
adapter (M).
Reassembly
Z Introduce the spring (K) into the adapter (M).
Z Place the 3 balls (J) into the radial holes of the
adapter (M) and use grease to prevent them from
falling.
Z Position the central ball (H) against the spring (K).
Z Slip the detent bush (I) onto a metal rod.
Z Using the metal rod, press the central ball (H) into
the adapter (M), then slide the detent bush (I) onto
the adapter, making sure that the 3 balls are still in
place.
NOTE: make sure that the orientation of the detent
bush is respected.
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3.2
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REXROTH CONTROL VALVES (PILOT MODELS)
The loader backhoe with hydraulic control (pilot models) differs basically from the mechanical loader
backhoe models for the reason that the controls driving the loader attachment and the stabilizers are hydraulic instead of being mechanical. By means of the
control levers located in the cab a control valve is
driven, that on its turn drives hydraulically the backhoe control valve, monitoring the backhoe loader
and the stabilizers.
The backhoe loader with hydraulic control is
equipped with two control valves:
Z Loader control valve: mounted on the right hand
side of the backhoe loader and provides oil flow to
the loader boom and front bucket.
Z Backhoe control valve: located in the rear part of
the chassis, it provides the oil flow to the backhoe
attachment, to the stabilizers and to the backhoe
bucket.
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Hydraulic system oil

Steering system oil
Load sensing oil
1.
2.
3.
4.
5.
6.
7.
8.
9.
Hydraulic tank
Pump
Power steering
Hand hammer control valve
Hand hammer
Backhoe hammer control valve
Backhoe hammer
41
Suction oil
Return to oil tank
Control circuit oil
10.
11.
12.
13.
14.
Oil cooler
Return line distributor block
Filter
Oil cooler by-pass valve
Solenoid valve for piloting hydraulic backhoe
control valve
15. Hydraulic control lever
16. Accumulator
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LOADER CONTROL VALVE

The loader control valve is mounted on the right side
of the machine adjacent to the pump. The valve assembly consists of two or three spool operated sections:
Z Loader lifting
Z Loader bucket
Z 4x1 loader bucket
Usually the loader control valve has three valve sections when is installed on the loader backhoe the 4x1
bucket.
A.
B.
C.
1.
2.
3.
4.
5.
6.
7.
4x1 loader bucket section

Loader bucket section
Lifting section
End cover
4x1 loader bucket relief valve
Loader bucket relief valve (rod end) 240 bar
Hydraulic speed relief valve 165 bar
Hydraulic speed solenoid
Inlet section
Loader bucket relief valve (piston end) 165 bar
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Removal
Lower the loader to the ground, with the bucket firmly
placed on the ground.
Stop the engine and relieve any residual pressure in
the backhoe and loader attachment systems by moving the relevant control levers through all operating
positions.
Disconnect the battery.
Clean the area around the control valve.
Identify and disconnect linkage, cables and each
hose connection to the control valve and plug the
hose ends. A drip tray will be required to catch oil
draining from inside the hoses.
Unscrew and remove clamping screws to chassis.
Remove the valve assembly from the machine.
Installation is the reverse of the removal procedure.
Disassembly
Unscrew and remove the three nuts (1). Tightening
torque 27 2 Nm. Slide out the three tie bars (2).
Disassemble the end cover (4), the section control

valve (4), (5) and (6), and the inlet section (7).
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BACKHOE CONTROL VALVE (WITH HYDRAULIC CONTROL)

The rear control valve is located in the rear part of the
loader backhoe. It consists of six or seven valve sections together with an inlet and outlet end cover.
Valve sections are:
Z Right-hand stabilizer
Z Stabilizer left
Z Lifting
Z Crowd
Z Swing
Z Backhoe bucket
Z Telescopic (optional)
K. Hydraulic diagram for center pivot models

(4WS)
W. Hydraulic diagram for sideshift models (4WS)
A. Right stabilizer section
B. Left stabilizer section
C. Dipper section
D. Bucket section
E. Swing section
F. Lifting section
G. Telescopic dipper section
H. Backhoe attachment travel lock valve (sideshift)
1. End cover
2. Inlet section
4. Backhoe bucket circuit relief valve (piston end) 220 bar
5.
6.
7.
8.
9.
10.
11.
12.
Swing circuit relief valve (piston end) - 205 bar

Boom system relief valve (piston end) - 315 bar
Pump flow balancer valve - 15 bar
Load sensing return to tank
Swing circuit relief valve (rod end) - 205 bar
Boom relief valve (rod end) - 240 bar
Telescopic relief valve (rod end) - 205 bar
Load sensing relief valve - 210 bar
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Removal
Position the loader backhoe on a hard level surface.
Lower the loader attachment to the ground.
Lower the stabilizers.
Position the dipper in the vertical position, with the
Stop the engine and relieve any residual pressure in
the backhoe and loader attachment systems by
Disconnect the battery.
Clean the area around the control valve.
Tag and identify the position of all hoses and hydraulic tubes.
Disconnect and plug all the hoses and all the hydraulic tubes.
Unscrew and remove clamping screws to chassis.
Remove the valve assembly from the loader backhoe.
Installation is removal procedure in reverse.
Disassembly
Unscrew and remove the three nuts (1), tightening
torque 27 2 Nm.
Slide out the three tie bars (2).
Disassemble the end cover (3), the sections control

valves (4), (5), (6), (7), (8), (9) and (10), the inlet section (11).
between the sections.
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Disassembly the inlet section.

Remove the pump flow balancer valve (13), the load
sensing relief valve (14) and the check valve (15)
from the inlet section (11).
Disassembly the outlet section.

(Sideshift version)
Unscrew the knob (16).
Remove the solenoid (17) and the 2 way valve (18).
Disassembly the shuttle valve (19).
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Disassembly of control valve sections (with hydraulic control)

In this section are indicated all possible solutions relevant to backhoe control valve sections with hydraulic control.
1. Secondary relief valve

2A. Pressure compensator with shock absorber
2B. Fixed pressure compensator
3.
4.
5.
6.
Check valve
Plug
Spring return system with guide
Spool
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Disassembly and reassembly hydraulic control

spool
Disassembly
Z Remove the screws (A), and the plate (B).
Z Extract the spring guides (C) and the springs (D).
Z Discard the seals (E).
Z Remove the spool (F) from the valve section.
Reassembly
Z Grease and install the spool (F) in the valve section.
Z Install the springs (D) in the caps (B).
Z Install the spring guides (C) in the springs (D).
Z Install new seals (E).
Z Install the cap assemblies on the valve section, install and tighten the screws (A) to a torque of 9 to
11 Nm.
Electrical detent system spool

Solenoid replacement (with spool pulled out)
Z Remove the 2 mounting screws (A) and the detent
system.
Z Unscrew the rear housing (B).
Z Remove the circlip (C), the spring and the coil.
Z Install a new solenoid (D).
Z Reassemble parts in reverse order.
Z Tightening torque:
screws (A) - 9 to 11 Nm
rear housing (B) - 1.8 to 2.2 Nm
Solenoid replacement (with spool pushed in)

Z Remove the solenoid (A).
Z Install a new solenoid.
Z Tightening torque - 18 to 22 Nm.
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3.3
SOLENOID VALVE FOR PILOTING THE BACKHOE CONTROL VALVE (WITH

HYDRAULIC CONTROL)
Solenoid valve is located under the cab floor and is

installed directly in the lower part of the chassis that
supports the operating levers. The solenoid valve is
installed with the pilot models and has the task to
transform the electrical controls, received from the
hydraulic control levers, in hydraulic controls and to
send them to the backhoe attachment control valve.
The module (A) is installed only on the machines
versions with telescopic dipper. If the machine is not
equipped with telescopic dipper, the solenoid valve
installed is of type (B); while if the telescopic dipper
is installed the solenoid valve can be of type (A) +
(B).
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If the loader backhoe is equipped with a telescopic

dipper and if the rear control valve contains an auxiliary section, the solenoid valve consists of valve (B)
and module (C).
Removal
Z Position the loader backhoe on a hard level surface.
Z Lower the loader attachment to the ground.
Z Lower the stabilizers.
Z Position the dipper in the vertical position, with the
Z Clean the area around the solenoid valve.
Z Tag and identify the position of all hoses and hydraulic tubes.
Z Disconnect and plug all the hoses and all the hydraulic tubes.
Z Unscrew and remove clamping screws to chassis
supporting the operating levers.
Z Remove the solenoid from the loader backhoe.
Z Installation is removal procedure in reverse.
Disassembly
Unscrew and remove the accumulator (1) from the
solenoid valve assy (2).
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Loosen and remove the three screws (3) and disassemble valve (4).
In case of necessity it is possible to disassemble the

various solenoid valves from the manifold blocks.
Loosen and remove the screws (6).
Disassemble the solenoid valves (7).
Loosen and remove the valve (9).

Remove the check valve (11) and the orifice (12).
Loosen and remove the solenoid valves (13).
Loosen and remove the solenoid valves (15).
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3.4
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RELIEF VALVES
The relief valves may be operated with anti-cavitation feature (1) or direct acting (2) and protect individual circuits from excessive pressure.
The backhoes, having this kind of control valves installed, are equipped with different relief valves.
Some of them are installed on the loader control
valve:
1. 4x1 loader bucket relief valve
2. Loader bucket relief valve (rod end) - 240 bar
3. Hydraulic speed relief valve - 165 bar
4. Loader bucket relief valve (piston end) - 165 bar
Some of them are installed on the backhoe control

valve:
2. Loader bucket relief valve (piston end) - 220 bar
3. Swing circuit relief valve (piston end) - 205 bar
4. Boom relief valve (piston end) - 315 bar
5. Swing circuit relief valve (rod end) - 205 bar
6. Boom relief valve (piston end) - 240 bar
7. Telescopic relief valve (rod end) - 205 bar
8. Load sensing relief valve - 210 bar
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53
Circuit relief valves operating

Relief valve inoperative
When the system is not subject to overload conditions pressure in the system is insufficient to overcome pilot valve spring pressure and move the valve
of its seat.
System pressure sensed on the larger rear face of
the poppet valve maintains the poppet and sleeve
firmly on their seats.
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
6. Control valve (cylinder) exhaust gallery
7. Cylinder supply gallery
Pilot valve operation
When the cylinder is subjected to shock forces, the
pressure increase in the cylinder supply gallery exceeds the pilot valve spring pressure: this valve lifts off
its seat. System pressure on the rear face of the poppet
valve escapes to tank between the sleeve poppet and
valve body causing a pressure differential between the
front and rear face of the poppet valve. The higher pressure in the cylinder supply gallery unseats the poppet
valve and moves the piston to seat against the pilot
valve.
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
F29539
F29540
F29541
Exhaust oil
High pressure oil
Exhaust oil
High pressure oil
Reduced pressure oil
Pilot and poppet valve operation

The excessive system pressure in the cylinder supply gallery now flows past the poppet valve to the
cylinder exhaust gallery and back to tank.
NOTE: during this operation the sleeve poppet is

held in the fully seated position by pressure oil.
1.
2.
3.
4.
5.
6.
7.
Sleeve
Poppet valve
Pilot valve
Pilot valve body
Piston
Control valve (cylinder) exhaust gallery
Cylinder supply gallery
High pressure oil

Exhaust oil
Reduced pressure oil
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54
Anti-cavitation operation
Circuit relief valves with an anti-cavitation feature
are fitted in circuits where rapid extension of the cylinder could create a void condition and permit the
transfer of oil from the high pressure side of a cylinder to the lower pressure (void) end of the cylinder.
When for example the boom is rapidly lowered and
the cylinder rod end circuit relief valve operates, oil
has been removed from the rod end of the cylinder
and a void created in the piston end. This oil is automatically replenished by the anti-cavitation device in
the opposite circuit relief valve as follows:
The void creates a pressure lower in the cylinder
supply gallery and back pressure in the control valve
exhaust gallery acts on the outer face of the sleeve
poppet moving it to the right.
Exhaust oil is then directed into the cylinder supply
gallery to stop cavitation.
2
1
5
High pressure oil
Anti-cavitation oil supply to cylinder
Relief valve exhaust oil
1. Anti-cavitation system pressure relief valve
2. Cylinder rod
3. System pressure relief valve
4. Control valve exhaust gallery

5. Spool
F29542
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Pilot-operated pressure relief valve with anti-cavitation feature subjected to overload and fully relieving
high-pressure oil
1. Sleeve
2. Poppet valve
3. Pilot valve
4. Pilot valve body
5. Piston
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F29543
Anti-cavitation cylinder resupply oil

Exhaust oil
Direct-acting pressure relief valve operation
High-pressure oil in the system is sensed in the cylinder supply gallery and acts on the surface of the
pressure relief valve poppet.
When pressure in the system exceeds the pressure
relief valve setting, the oil pressure lifts the poppet,
allowing excess pressure in the overloaded cylinder
to escape to the drain gallery.
6
A. Direct acting circuit relief valve
Valve not subjected to overload conditions
B. Direct acting circuit relief valve
Valve subjected to overload conditions
1. Relief valve seat
2. Relief valve poppet
3. Valve pressure adjusting screw
4. Spring
5. Control valve exhaust gallery
6. Cylinder supply oil
5
Exhaust oil
High-pressure system oil
F29544
F29545
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Overhaul
IMPORTANT: before removing relief valves from
the machine lower the loader and backhoe to the
ground, switch engine off and relieve all pressure in
circuits by moving the backhoe, loader, and telescopic dipper controls through all operating positions. If the pressure relief valves are suspected of
contamination, they may be disassembled and inspected for wear. However, remember to restore the
correct pressure.
The relief valves contain no serviceable components
with the exception of the external O-rings and
square section seals.
During disassembly examine the poppet and seat in
the plunger assembly for a complete seating surface.
Pilot operated relief valve
1.
2.
3.
4.
5.
6.
7.
8.
Body
Shutter
Spring
Spring
O-ring
O-ring
Valve
Cover
9.
10.
11.
12.
13.
14.
15.
16.
O-ring
Nut
O-ring
Adjuster screw
Spring
Pilot valve
Poppet
Piston
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Direct acting circuit relief valve
1.
2.
3.
4.
5.
Body
Poppet
Spring
Spring
Shim
6.
7.
8.
9.
10.
Cover
O-ring
Nut
O-ring
Adjuster screw
7.
8.
9.
10.
11.
Piston
Poppet
Valve
Inner body
Spring seat
Loader bucket relief valve
1.
2.
3.
4.
5.
6.
Relief valve assembly

Spring
Nut
Body
Adjuster screw
Spring
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System pressure relief valve adjustment

After overhaul, the pressure relief valves of the system must be tested and adjusted using a suitable
hand pump (1), a 275 bar pressure gauge and a
V. L. Churchill test kit (2).
The hand pump must be attached to inlet port I and

the drain hose to the outlet port T of test block using
suitable 1/2 inch BSP (British Standard Pipe) adaptors.
The pressure gauge may be connected to either the
hand pump as shown or to the 3/8 UNF threaded
port G in the test block.
Remove plug and insert valve to be tested into the
appropriate port in the test block as follows:
A. Stabilizer and backhoe relief valves
B. Loader bucket relief valves
C. Unload valve
NOTE: a special removable insert, which is part of

the test block, is installed in the bottom part of the
port used for testing the loader attachment valve. If
difficulty is experienced in screwing the loader valve
into the test block, check that the insert is fully seated and correctly installed. When correctly installed
the O-ring (3) on the face of the insert should be visible.
Operate hand pump and record maximum pressure

reading on gauge. Compare pressure values with
previous specifications.
IMPORTANT: before removing the valve from the
test block, release the pressure in the system using
the vent valve on the hand pump.
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To adjust all relief valves with the exception of the

loader bucket relief valve remove the valve cap,
loosen locknut and turn adjuster to obtain correct
pressure.
NOTE: relief valves must not be set outside off the
specified range.
Loader bucket relief valve adjustment

NOTE: if the loader bucket circuit relief valve requires adjustment, the special adjusting tool supplied with the test kit is required as described below.
Hold relief valve in vice and using wrench supplied
with tool, unscrew the internal valve assembly from
the valve body.
Screw the internal valve assembly (2) into the body
of the adjusting tool (1).
Install valve into test block and operate hand pump

until valve is pressurized to 170 bar.
Using the special spanner supplied, loosen the locknut on the end of the valve and adjust pressure setting using Allen wrench.
Operate hand pump and recheck pressure.
When pressure setting is correct tighten locknut and
release pressure in circuit using the vent valve on
the hand pump.
Remove the valve and, using a 3/8 16 UNC screw,
remove the insert. Reassemble the valve and install
it on the test block.
Operate hand pump and recheck pressure.
If pressure is now lower than that recorded with the
insert installed it is an indication that the anti-cavitation feature of the valve is leaking and the valve requires overhaul or replacement.
NOTE: the insert isolates the anti-cavitation feature
of the valve. When reassembling the insert into the
test block ensure it is installed correctly. When correctly installed the O-ring (3) on the face of the insert
should be visible.
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3.5
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ACCUMULATOR GLIDE RIDE PARKER
Technical specifications
Capacity (gas) ...........................................................................................................................................2 litres
Capacity (oil) ........................................................................................................................................1.84 litres
Precharge............................................................................................................................................ 30 1 bar
Maintenance
Z Check the gas pre-charge pressure regularly during the first few weeks of operation, and then at suitable intervals afterwards based on this initial experience.
Z Carry out a visual examination of the accumulator periodically in order to detect any early signs of deterioration such as corrosion, deformation etc.
Z Comply with the regulatory provisions concerning the monitoring of operational equipment.
Z Before removal, it is vital to ensure that there is no residual hydraulic pressure in the accumulator. Discharge
the gas side of the accumulator using a Parker UCA charging and gauging assembly before carrying out any
maintenance operations.
Safety
Charging must be carried out by qualified personnel.
Before taking any readings or pressurizing with nitrogen, the accumulator must be isolated from the hydraulic
system and the fluid side discharged in order to depressurize it.
Use only nitrogen (N2) to pressurize the accumulator.
Danger of Explosion - Never Charge with Oxygen
The types of nitrogen permitted are: type S (99.8% pure); type R (99.99% pure); type U (99.993% pure).
If the pressure of the gas contained in the nitrogen bottle is greater than the maximum permissible operating
pressure of the accumulator, a pressure regulator must be fitted to the nitrogen bottle.
Parker recommends that the precharge should be checked during the first week following commissioning of
the system.
Thereafter, it should be checked every three months, or at intervals determined by the Manufacturer.
The Effect of Temperature on Precharge Pressure
In order to compensate for the difference in pressure at ambient and operating temperatures, it is recommended that the precharge pressure po should be adjusted to reflect the operating temperature of the system, using
the correction factor equations and relevant table.
Warning - Stabilization
The process of charging or discharging an accumulator with nitrogen causes a temperature change which is
transmitted to the surrounding air as the temperature of the accumulator stabilizes. To allow for the effects of
temperature transfer, the accumulator should be allowed to stand for a minimum of 15 minutes before a final
reading of the precharge pressure is taken.
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Checking and Adjusting Precharge Pressure

The precharge pressure of an ACP Series accumulator may be checked, and nitrogen filled or vented, using
the UCA Universal Charging & Gauging kit tool 380002714.
The kit assembly is screwed onto the accumulators gas valve, allowing the precharge pressure to be checked
or reduced. If the precharge pressure is to be increased, the UCA can be connected to the nitrogen source with
the hose supplied. The kit is supplied with two pressure gauges, reading 0-25 bar and 0-250 bar; where a different pressure range is required, a commercially-available pressure gauge may be used.
UCA kit 380002714 see drawing
A. Inflation valve
B. Bleed valve
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
UCA
Adapter (long)
Adapter (short)
Adapter (insert)
Pressure gauge
Protective cap - gauge port
Collar - gas port
Knurled protective cap - filling port
Hose (G1/4 fitting, 60 cone) with O-ring
Valve
Z Remove the protective cover and cap (11) from the

accumulator, to gain access to the gas valve (12).
Z Select the appropriate pressure gauge (5) for the
pressure to be checked, remove the protective cap
(6) and attach the gauge to the UCA (1).
Z Make sure that the bleed valve (B) is fully closed
and that the inflation valve (A) is in the fully raised
position by turning the handwheel in an counterclockwise direction.
Z Assemble the short adapter and adapter insert (3
and 4), screw onto the gas valve (13) and hand
tighten.
Z Screw the UCA onto the adapter. Position the assembly to permit easy reading of the gauge, then
hand tighten the collar (7).
Z Open the inflation valve (A) by screwing the handwheel clockwise until the inflation pressure registers on the gauge.
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Readings and Results

One of three conditions will apply: the precharge pressure in the accumulator will be correct, or it will be too
high or too low.
Nitrogen Pressure po is Correct
Z Screw the handwheel (A) counterclockwise to close the accumulator gas valve.
Z Slacken the bleed valve (B) to release pressure in the UCA.
Z Unscrew the UCA from the adapter.
Z Unscrew the adapters from the accumulator gas valve.
Nitrogen Pressure po is Too High
Z Slacken the bleed valve (B) to vent nitrogen from the accumulator until, after stabilization, the desired pressure po is registered. Nitrogen vents into the air.
Z Tighten the bleed valve (B) once the desired filling pressure is reached.
Z Unscrew the UCA from the adapter.
Z Unscrew the adapters from the accumulator gas valve.
Nitrogen Pressure po is Too Low
Z Close the inflation valve (A) by screwing the handwheel counterclockwise.
Z Remove the cap (8).
Z Connect the end of the hose (9) to the valve (10).
Z Connect the other end of the hose to the nitrogen source.
Z Progressively open the valve on the nitrogen source.
Z Screw the handwheel (A) clockwise to admit the pressurized gas, taking particular care if the accumulator has
a small capacity.
Z When pressure po is reached, close the valve on the nitrogen source. To allow for the effects of temperature
transfer, the accumulator should be allowed to stand for a minimum of 15 minutes to allow the temperature to
stabilize before a final reading of the precharge pressure is taken.
Z Remove the hose carefully, to release internal pressure.
Z Refit the cap (8) on the valve (10).
Z Unscrew the UCA from the adapter(s).
Unscrew the adapters from the accumulator gas valve. After removing the UCA and adapter(s), make sure that
the accumulator gas valve (13) is sealing effectively. Refit the gas valve dust cap (12) and replace the protective cover (11).
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4.
HYDRAULIC SWING SYSTEM
4.1
The hydraulic swing system has two versions:

Z it can shift laterally with the backhoe attachment
because installed directly on the sideshift carriage
performing the shifting. This is possible only on the
loader backhoes with sideshift version.
Z it is fixed because it is installed directly on the chassis. This is possible only on loader backhoes with
center pivot version.
The backhoe boom and digging elements can be
moved in an arc about the main chassis of 180 degrees.
This movement is obtained by the use of two hydraulic cylinders (1) coupled between the main chassis
and swing post.
The cylinders act directly on the swing post, without
the use of any connecting links or bell cranks.
Each cylinder is free to rotate, around two pivots (3),
while the stem comes out or retracts inside of the
cylinder body (2).
As each cylinder extends or retracts and the swing
post rotates, the cylinders turn in a horizontal plate,
pivoting on the headstocks within the carriage.
Each cylinder is double acting and as hydraulic oil is
fed to a cylinder to turn the swing post, one cylinder
pushes and the other cylinder pulls to perform the
swing cycle.
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4.2
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HYDRAULIC OIL FLOW
Hydraulic feed to the swing cylinders is controlled by

the swing section of the backhoe attachment control
valve, which contains pilot-operated pressure relief
valves with anti-cavitation feature to protect the system and the cylinders, should an overload condition
occur.
The diagram illustrates the operation of the swing
circuit when retracting the right-hand cylinder (4)
and extending the left-hand cylinder (5) in order to
swing the backhoe attachment to the right.
When swinging the backhoe to the left the oil flows
are reversed and exactly the same principle of operation applies.
Oil flow for a right hand swing is as follows:
When the swing control is operated the control valve
directs oil flow to the rod end of the right hand cylinder.
The flow of oil at pump pressure lifts the one way restrictor (2) of its seat allowing the flow to continue
unrestricted to the inlet port of the piston end of the
left hand cylinder.
System pressure increases causing the right hand
cylinder to retract and the left hand cylinder to extend.
As the cylinders move, displaced oil on the piston
side of the left hand cylinder flows towards the one
way restrictor (7) in the inlet port on the rod end of
the right hand cylinder.
The oil flow moves the restrictor to the restrict position which limits the flow of oil and creates a back
pressure (1st stage restricted return oil) in the right
hand cylinder.
The restricted flow of oil passes through restrictor
(7) into the rod end of the left hand cylinder before
returning to the control valve and back to tank.
The spool in the swing control valve assembly (1) is
designed such that during operation oil can flow
freely through the port directing oil flow to the swing
cylinders but restricts the flow returning oil back to
tank.
This restriction is achieved using metering lands
machined into the lands of the spool and creates a
secondary back pressure (2nd stage restricted return oil) in the rod end of the cylinder.
By allowing oil to flow unrestricted to the power side
of the cylinder and be restricted on the exhaust side
a smooth controlled swing of the backhoe at optimum speed is achieved.
When the swing system reaches the last 20-25 of
travel the sliding restrictor in the end of the piston
rod touches the outlet port in the cylinder barrel.
This further restricts the flow of oil drained from the
cylinder. As the piston moves towards the end of its
stroke, the sliding restrictor is gently pushed down
towards the centre of the cylinder rod, allowing a
progressive and controlled stop of the swing cycle.
If the swing control valve is suddenly returned to

neutral mid-way through a full power swing the supply and exhaust ports in the main control valve are
totally blocked.
The momentum of the swinging backhoe assembly
if not controlled will make the machine extremely unstable.
To prevent this from occurring, the system pressure
relief valves operate and drain the oil until an excess
pressure is detected. When the relief valve operates
the cylinder rod will move and a void will be created
in the low pressure side of the cylinder. The anticavitation feature in the relief valves prevents the
void from creating by transferring the drain oil from
the side of the system where an excess pressure
occurred to the low pressure side.
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4
F29480
Pump pressure oil

1st stage restricted return oil
2nd stage restricted return oil
Return to oil tank
1.
2.
3.
4.
5.
6.
7.
Control valve swing section

One way restrictor
Cushioning rod
Right hand cylinder
Left hand cylinder
Cushioning rod
One way restrictor
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5.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
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HYDRAULIC CYLINDERS
Loader attachment boom cylinder

Loader bucket cylinder
4x1 loader bucket cylinder
Backhoe boom cylinder
Backhoe dipper cylinder
Backhoe bucket cylinder
Telescopic cylinder
Swing backhoe cylinder
Stabilizer cylinder (center pivot models)
Stabilizer cylinder (sideshift models)
Backhoe attachment travel lock cylinder (sideshift models)
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5.1
LOADER ATTACHMENT BOOM CYLINDER
2WS
(1) Stroke
(2) Completely retracted
4WS
(1) Stroke
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CYLINDER REMOVAL
Park machine on a flat surface. Raise the loader sufficiently to allow the loader cylinder pin to be removed.
Remove the loader bucket and support the arm using a suitable stand or hoist.
SWARNING
Always ensure loader is fully supported. Do not work
under or near an unsupported loader or personal injury may occur.
Relieve the residual pressure in the system by moving the loader control lever through all operating positions.
Stop the engine.
Support the cylinder using sling and suitable hoist.
Disconnect the hydraulic hoses. Cap or plug all exposed openings.
F30317
F30318
Disconnect the hydraulic hoses.

Remove the snap ring (1) and the spacer (2).
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Remove the ring (3) and the pin (4).

Use a hammer to extract the rod pin (5).
Remove the loader attachment boom cylinder.
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DISASSEMBLY CYLINDER
1.
2.
3.
4.
5.
6.
7.
8.
Cylinder rod
Bushing
Wiper ring
Ring seal
Ring seal
Guide bush
Cylinder head
Safety screw
The disassembly procedure below starts on the

premise that the hydraulic lines have already been
removed.
SWARNING
Cylinder weight (2WS) = 32.5 kg.
Cylinder weight (4WS) = 41.3 kg.
Lift and securely place the cylinder on a workbench.
Be sure that the cylinder is placed horizontally. Drain
hydraulic oil from the cylinder.
9.
10.
11.
12.
13.
14.
15.
16.
Back-up ring
O-ring
Piston
Piston gasket
Piston guide
Screw
Cylinder tube
Bushing
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Support the cylinder rod (1).

Unscrew and remove the safety screw (8).
Use the wrench 380000725 to loose the cylinder
head (7).
If necessary gently heat the gland carrier to soften
the thread sealant applied during manufacture.
Remove the cylinder head (7) from the cylinder barrel (15) using a plastic hammer. Remove the cylinder
rod (1) and the cylinder head (7).
IMPORTANT: be sure to pull the cylinder rod (1)
straight so as not to damage the sliding surfaces.
Loosen and remove the screw (14). Extract the piston (11) and the cylinder head (7) from the cylinder
rod (1).
Only if necessary:
Z Remove the wiper ring (3), the seal rings (4) and
(5), the guide bush (6) and the back-up ring (9) with
the O-ring (10) from the cylinder head (7).
Z Remove the piston seal (12) and the piston guide
ring (13) from the piston (11).
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5.2
Copyright
LOADER BUCKET CYLINDER
2WS
(1) Stroke
4WS
(1) Stroke
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CYLINDER REMOVAL
Park machine on a flat surface and position the
bucket firmly on the ground.
Support the cylinder using sling and suitable hoist.
Support the link rods.

Remove the snap ring (1) with the spacer (2).
Remove the pin (3) using an hammer.
Remove the snap ring (4) with the spacer (5).

Remove the pin (6) using an hammer.
Remove the loader bucket cylinder.
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1.
2.
3.
4.
5.
6.
7.
8.
Bushing
Cylinder rod
Wiper ring
Ring seal
Ring seal
Cylinder head
Snap ring
Back-up ring
The disassembly procedure that follows takes into

consideration the hydraulic piping already disassembled.
SWARNING
Cylinder weight: 32.5 kg
9.
10.
11.
12.
13.
14.
15.
O-ring
Piston
Piston gasket
Piston guide
Screw
Cylinder tube
Bushing
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Support the cylinder rod (2) and use the wrench

380000722 to loosen the cylinder head (6).
Remove the stop ring (7)

Extract the cylinder head (6) from the cylinder barrel
(14) by tapping it with a plastic hammer. Remove the
cylinder rod (2) and the cylinder head (6).
Loosen and remove the screw (13).

Extract the piston (10) and the cylinder head (6) from
the cylinder rod (2).
Only if necessary:
Z remove the wiper ring (3), the seal rings (4) and (5),
the back-up ring (8) with the O-ring (9) from the cylinder head (6);
Z remove the piston seal (11) and the piston guide
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5.3
1.
2.
3.
4.
Copyright
4X1 LOADER BUCKET CYLINDER
Cylinder rod pin

Dowel
Bucket
Cylinder
CYLINDER REMOVAL
5. Dowel
6. Nut
7. Cylinder bottom pin
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Unscrew and remove the clamping screws of the

cover (C). Remove the cover (C).
Remove the pin (2). Slide out the rod pin (1) with an
hammer.
Unscrew and remove the nut (6) and the dowel (5).
Slide out the lower pin (7) with an hammer.
Remove the 4x1 loader bucket cylinder.
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Copyright
1.
2.
3.
4.
5.
6.
Cylinder tube
Piston
Pin
O-ring
Piston guide
O-ring
7.
8.
9.
10.
11.
Cylinder head
Gasket
Wiper ring
Cylinder rod
Bushing
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5.4
BACKHOE BOOM CYLINDER
(1) Stroke
CYLINDER REMOVAL
Park the machine on a flat surface and position the
backhoe on the ground. Support the backhoe elements for cylinder removal using a suitable stand.
SWARNING
Always support the structural members so that they
will be stable and safe to work around.
Stop the engine and move the backhoe attachment
control levers through all operating positions to relieve any residual pressures in the system.
Position a sling or other suitable lifting equipment

around the cylinder.
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Loosen and remove the screw (1). Slide out the rod
pin (2) with an hammer.
NOTE: the barrel end of the dipper cylinder and the
rod end of the boom cylinder use a common pin (2).
If the boom cylinder has to be disassembled, slide
out the pin (2) only partially, then remove the cylinder rod and finally reinsert the pin.
If necessary, use hydraulic power to very slowly retract the cylinder. In this way, the rod moves away
from the attaching point.
Disconnect the hydraulic hoses. Remove the stop

ring (3) and slide out the head pin (4).
NOTE: accurate positioning of the cylinder prior to
hose disconnection will aid pin removal.
Remove the backhoe attachment boom cylinder.
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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Wiper ring
Bushing
Cylinder rod
Wiper ring
Ring seal
Ring seal
Guide bush
Safety screw
Cylinder head
Back-up ring

SWARNING
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
O-ring
Piston guide
Piston gasket
Piston
Piston gasket
Washer
Screw
Cylinder tube
Bushing
Wiper ring
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Remove the safety screw (8). Use the wrench
380000724 to loose the cylinder head (9).

Loosen and remove the screw (17) with the relevant

washer (16). Extract the piston (14) and the cylinder
head (9) from the cylinder rod (3).
Only if necessary:
the guide bush (7) and the back-up ring (10) with
the O-ring (11) from the cylinder head (9);
Z remove the piston guide ring (12) and the piston
seals (13) and (15) from the piston (14).
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5.5
BACKHOE ATTACHMENT DIPPER CYLINDER
(1) Stroke
CYLINDER REMOVAL
SWARNING

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Loosen and remove the nut (1) and the screw (2).
Slide out the rod pin (3) with an hammer.
If necessary, use hydraulic power to very slowly retract the cylinder. In this way, the rod moves away
from the attaching point.
Disconnect the hydraulic hoses. Loosen and remove

the screw (4). Slide out the rod pin (5) with an hammer.
The tube end of the dipper cylinder and rod end of
the boom cylinder use a common pin (5).
Therefore before shifting the dig cylinder, support
the boom cylinder with a rope or an hoist.
Remove the backhoe dipper cylinder.
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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Wiper ring
Bushing
Cylinder rod
Wiper ring
Ring seal
Ring seal
Guide bush
Safety screw
Cylinder head
Back-up ring

SWARNING
Cylinder weight: 64 kg
11.
12.
13.
14.
15.
16.
17.
18.
19.
O-ring
Piston gasket
Piston guide
Piston
Washer
Screw
Cylinder tube
Bushing
Wiper ring
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Unscrew and remove the safety screw (8). Use the
wrench 380000724 to loose the cylinder head (9).

Loosen and remove the screw (16) with the washer

(15). Extract the piston (14) and the cylinder head (9)
from the cylinder rod (3).
Only if necessary:
Z remove the piston guide rings (13) and the piston
seal (12) from the piston (14).
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5.6
BACKHOE BUCKET CYLINDER
(1) Stroke
CYLINDER REMOVAL
Park the machine on a flat surface. Lay the backhoe
SWARNING

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Remove the stop ring (1) with the shim (2). Slide out
the pin (3) with an hammer and pay attention to levers.
If necessary use hydraulic power to very slowly retract the cylinder.
Disconnect the hydraulic hoses. Unscrew and remove the screw (4) and slide out the pin (5) with an
hammer.
Remove the backhoe bucket cylinder.
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1.
2.
3.
4.
5.
6.
7.
8.
9.
Wiper ring
Bushing
Cylinder rod
Wiper ring
Ring seal
Ring seal
Guide bush
Safety screw
Cylinder head

SWARNING
10.
11.
12.
13.
14.
15.
16.
17.
18.
Back-up ring
O-ring
Piston gasket
Piston guide
Piston
Screw
Cylinder tube
Bushing
Wiper ring
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Remove the safety screw (8). Use the wrench

rod (3).
Only if necessary:
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5.7
TELESCOPIC CYLINDER
(1) Stroke
CYLINDER REMOVAL
SWARNING
Remove the snap ring (1). Hammer to slide out the

pin (2) from the other side.
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Disconnect the hydraulic hoses (3), at dipper cylinder and support cylinder using suitable hoist.
Remove the snap ring (5). Hammer to slide out the
pin (4) from the other side.
Remove the telescopic cylinder.
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1.
2.
3.
4.
5.
6.
7.
Cylinder rod
Wiper ring
Ring seal
Ring seal
Guide bush
Safety screw
Cylinder head

SWARNING
8.
9.
10.
11.
12.
13.
14.
Back-up ring
O-ring
Piston gasket
Piston guide
Piston
Screw
Cylinder tube
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rod (1).
Only if necessary:
the guide bush (5), the O-ring (9) with the back-up
ring (8) from the cylinder head (7);
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5.8
4WS STABILIZER CYLINDER - CENTER PIVOT
(1) Stroke
CYLINDER REMOVAL
Make sure that the backhoe loader is locked in the
transfer position or parked in a safety work position.
Lower the stabilizers to the ground.
Support the cylinder safely with suitable belt and

hoist.
Remove the snap ring (1) and the shim (2).
Extract the pin (3) with a hammer. Using the hydraulic power, retract the cylinder very slowly.
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With engine stopped, release any residual pressure

by moving the control levers of stabilizers.
Disconnect all hydraulic hoses. Remove the snap
ring (4) and the shim (5). Hammer to slide out the pin
(6).
Remove the stabilizer cylinder.
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DISASSEMBLY STABILIZER CYLINDER - CENTER PIVOT
1.
2.
3.
4.
5.
6.
7.
Cylinder rod
Wiper ring
Ring seal
Ring seal
Guide bush
Safety screw
Cylinder head

SWARNING
8.
9.
10.
11.
12.
13.
14.
Back-up ring
O-ring
Piston gasket
Piston guide
Piston
Screw
Cylinder tube
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rod (1).
Only if necessary:
the guide bush (5), the O-ring (9) with the back-up
ring (8) from the cylinder head (7);
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5.9
STABILIZER CYLINDER - SIDESHIFT
(1) Stroke
CYLINDER REMOVAL
bucket on the ground.

Relieve possible residual pressures in the system by
moving the loader attachment control lever through
all operating positions.
Loosen and remove the screw (1) and the nut (2).
Extract the pin (3) to release the cylinder rod.
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Disconnect the hydraulic tubes at the top of the stabilizer.

Remove the snap ring (4) and extract the pin (5).
Screw in an eye screw (6) on the cylinder and connect a rope or a chain.
Lift and remove the stabilizer cylinder.
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1.
2.
3.
4.
5.
6.
7.
Cylinder rod
Wiper ring
Ring seal
Ring seal
Cylinder head
Snap ring
Back-up ring

SWARNING
Lift and place the cylinder on a workbench and secure it to a vice. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from the cylinder.
8.
9.
10.
11.
12.
13.
O-ring
Piston
Piston guide
Piston gasket
Screw
Cylinder tube
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Remove the stop ring (6). Use the wrench

rod (1).
Only if necessary:
Z remove the wiper ring (2), the seal rings (3) and (4)
and the back-up ring (7) with the O-ring (8) from the
cylinder head (5);
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5.10 SWING CYLINDER
(1) Stroke
CYLINDER REMOVAL
SWARNING
Loosen and remove the nuts (1). Slide out the screw
(2) from the opposite side. Now the pin (3) can come
out and release the rod cylinder. If necessary hammer to help the pin (3) to come out.
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Disconnect the feed and return hose to the cylinders

and cap all exposed openings.
Loosen and remove the nuts (4) and the screws (5)
(from both sides).
Now it is possible to remove the support (6).
Carefully lift and remove the swing cylinder from the

swing bracket.
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1.
2.
3.
4.
5.
6.
7.
8.
9.
Bushing
Wiper ring
Cylinder rod
Wiper ring
Ring seal
Ring seal
Guide bush
Bushing
Ring seal

SWARNING
Lift and place the cylinder on a workbench and secure it to a vice. Be sure that the cylinder is placed
horizontally. Drain hydraulic oil from the cylinder.
10.
11.
12.
13.
14.
15.
16.
17.
Trunnion
O-ring
Back-up ring
Piston gasket
Piston guide
Piston
Lock retaining piston
Cylinder tube
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Use the wrench 380000725 to loose the trunnion

(10).
Remove the rod assy with the trunnion and the piston assy.
Unscrew and remove the piston lock (16). Disassembly the cylinder rod (3) and piston assy (15) and
the trunnion (10) complete with gaskets.
Check the bushings (8) status.
Only if necessary:
the O-ring (11) from the king pin (10).
Z remove the piston seal (13) and the piston guide
ASSEMBLY AND INSTALLATION

Reassembly follows the disassembly procedure in
reverse whilst observing the following:
1. Tighten the piston lock retaining to a torque of
1400 - 1540 Nm.
2. Tighten swing cylinder plate retaining screws to
a torque of 607 Nm.
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5.11 BACKHOE ATTACHMENT SIDESHIFT CYLINDER - SIDESHIFT

On the loader backhoe there are 4 sideshift lock cylinders for the backhoe attachment. Their function is
to lock the carriage once the backhoe attachment is
ready in the digging position.
The cylinder consists of:
1. Body
2. Cylinder
3. Seals
CYLINDER REMOVAL
bucket on the ground.
Position the backhoe support in the centre of the machine and lower the backhoe on the ground.
Relieve the residual pressure in the system by moving the control levers through all operating positions.
Disconnect the line (1).

Loosen and remove the two screws (2). Now it is
possible to remove the whole cylinder (3).
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5.12 SPECIAL TOOLS

P/N CNH
DESCRIPTION
APPLICATION
380000721
Wrench
Telescopic dipper cylinder head

Stabilizer cylinder head (sideshift)
380000722
Wrench
Loader bucket cylinder head
380000724
Wrench
Backhoe boom cylinder head

Backhoe dipper cylinder head
380000725
Wrench
Backhoe bucket cylinder head

Swing cylinder head
Loader cylinder head
380000726
Wrench
Stabilizer cylinder head (center pivot)
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6.
HYDRAULIC CONTROL LEVERS
6.1
SPECIFICATIONS
Weight
109
5.1 5.3 kg
Spool stroke
7.55 mm
SPECIAL TORQUE SETTINGS
Maximum permissible on the hydraulic control lever
80 Nm
Control block retaining screw
30 Nm
Control block universal joint
50 Nm
Control block nut
40 Nm
Lower body screw
50 Nm
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6.2
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1. CONTROL CANCELLATION SWITCH: with this

switch in the ON (alight) position, all the backhoe attachment hydraulic controls are functional.
2. LEFT-HAND HYDRAULIC CONTROL LEVER:
the left-hand hydraulic control lever controls attachment swing and the boom or the dipper (depending on the control pattern adopted).
3. RIGHT-HAND HYDRAULIC CONTROL LEVER: the right-hand hydraulic control lever controls the bucket and the boom or the dipper
(depending on the control pattern adopted).
NOTE: the operating speed depends on the angle of
movement of the control levers. In intermediate position, two movements may be obtained simultaneously.
4. STABILIZER CONTROLS: the right-hand control is for the right-hand stabilizer and the lefthand control is for the left-hand stabilizer.
5. CONTROL PATTERN CHANGE SWITCH: this
switch is used for changing the standard control
pattern to the ISO pattern.
6. TELESCOPIC DIPPER CONTROLS: (proportional controls) (If fitted).

Press the right-hand button to extend the telescopic dipper.
Press the left-hand button to retract the telescopic dipper.
7. WRIST RESTS: the wrist rests may be adjusted
to the required height.
8. HYDRAULIC CONTROL ARM TILT ADJUSTMENT: these controls are used for the fore/aft
and left/right adjustment of the arm.
9. WARNING HORN BUTTON: press the tip of the
left-hand hydraulic control lever to sound the
horn (momentary action).
10. CONTROLS OF AUXILIARY BIDIRECTIONAL
SECTION (If fitted): proportional buttons for the
activation of the additional attachment.
11. DECELERATOR BUTTON:
By pressing this button the engine rpm sets to
idle run. During this phase, the accelerator knob
and pedal are disabled.
By pressing the button again, the engine rpm is
restored and the accelerator knob and pedal are
functional again.
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RIGHT HAND HYDRAULIC CONTROL LEVER
1.
2.
3.
4.
5.
6.
7.
8.
9.
Valve
Plate
Screw
Nut
Boot
Connector
Wedge
Half handle
Screw
10.
11.
12.
13.
14.
15.
16.
17.
Half handle
Cover
Switches
Washer
Spacer
Clip
Clip
Plugs [if the switches (12) are not fitted]
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LEFT HAND CONTROL LEVER
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Valve
Plate
Screw
Nut
Boot
Connector
Wedge
Half handle
Screw
Half handle
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Cover
Switch push button (horn)
Washer
Spacer
Clip
Clip
Plugs [if the switches (18) are not fitted]
Switch push buttons (aux bi-dir)
Connector
Wedge
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6.3
Disassembly
Release pressure in the hydraulic circuits using the
following procedure: turn the starter switch key to ON
but do not start the engine. Turn pilot control cancellation switch to the ON position. Move both joysticks
in all directions. Turn the starter switch key to OFF.
Disconnect the negative battery cables.
Z Mark the position of the lever parts (see the exploded view on previous pages).
Z Remove the knob (P) and the support (S).
Z Remove the bracket (O) with the relevant screws
(with left hydraulic control lever).
Z Remove the decal (D), the mounting plate (D1) and

the detach the connectors (Q) (with left hydraulic
control lever).
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Z Pull out both switches (I) and the detach relevant

connectors (Q1) (with right control lever).
Z Remove the knob (P1) in the rear section of control

lever.
Z Remove the screws (V) and the plate (N).
Z Lift the rubber boot (RL) for left control lever and
the rubber boot (RR) for right control lever.
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Z Tag all hydraulic hoses before disconnecting them.

Disconnect all hoses (H).
Z Disconnect all connectors (Q2).
Z Remove the screws (V1) and take out control lever

from the column.
Z Remove the screws (9). Separate the half handles

(8) and (10). Remove the cap (11).
Unscrews the nut (4) and remove the screw (3).
Remove the spacers (14). Remove the boots (5).
Remove the plate (2).
Reassembly
To reassemble the control levers, proceed in the reverse order to that of removal.
Follow the marks made during disassembly, and tighten the nut (4) to a torque of 36 to 44 Nm.
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6.4
Copyright
CONTROL LEVER VALVE
P. Supply
T. Return to tank
Right valve (dipper/bucket)
1. Retracting the dipper
2. Opening the backhoe bucket
3. Extending the dipper
4. Closing the backhoe bucket
Left valve (backhoe/swing)

1. Lifting
2. Right swinging
3. Lowering
4. Left swinging
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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Universal joint cam

Plate
Shim
Upper body
Rod guide
Ring seal
Ring seal
Rod
Spring guide
Spring
Shim
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Cover
Safety ring
Spring
Spool
Shims
Valve
O-ring
Lower body
O-ring
O-ring
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HYDRAULIC CONTROL LEVER VALVE OVERHAUL

Disassembly
1. Mark the direction of installation of all disassembled parts.
2. Remove the U/J cam (1) using a key.
3. Remove the plate (2).
4. Remove the shim (3) from the upper body (4).
5. Extract the rod guide (5) and replace the seal
rings (6) and (7).
6. Drift the rod (8) out.
7. Remove the spring guide (9), the spring (10)
and the shims (11).
8. Extract the spool assembly.
9. Hold the cover (12) and remove the safety ring
(13).
10. Remove the spring (14) and the spool (15).
11. Remove and note the thickness of the shims
(16).
12. Proceed in the same manner for the other rods.
13. Secure the upper body (4) in a vice.
14. Loosen and remove the screw (17) using a key
and replace the O-ring (18).
15. Separate the upper (4) and lower (19) bodies

and replace the seal rings (20) and (21).
Reassembly
1. To reassemble, proceed in the reverse order to
that of removal.
2. In the case of reassembly without changing the
U/J cam (1), put the same value of shims (3) as
those in place.
3. After changing the U/J cam (1) adjust the pressure of the cam on the rods.
4. Install a 2 mm shim (3), check that the recessing
of the push-rods is less than 0.2 mm, modify the
shimming to more or less if required.
5. Assemble the new seal rings (6), (7) and O-rings
(18), (20) and (21).
6. Lubricate the moving parts.
7. Apply brake thread fluid on the threads of the U/
J cam (1) and the screw (17).
8. Tighten the cam (1) to 50 Nm and the screw (17)
to 50 Nm.
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7.
FAULT FINDING
7.1
PRELIMINARY CHECKS
If fault finding, pressure and flow testing is carried out

in a systematic manner and the results analyzed, the
malfunction can be readily and accurately identified.
If short-cuts, assumptions and guesses are made,
unnecessary component disassembly or replacement could result. Follow the step-by-step procedures outlined below.
As a first step in the fault finding procedure, several
preliminary checks should be made. These checks
are important because, once they have been performed, they need no longer be considered as a possible cause of the immediate or reported
malfunction.
Z Check that the hydraulic oil is at the correct level
and of the correct specification.
Z Check the loader, backhoe or any additional accessory such as hydraulic bucket, hammers etc., for
correct assembly or installation and additionally for
signs of external damage that might cause gross
misalignment of structural members.
Z Check in more detail for other mechanical damage
such as kinked, twisted, worn or decayed hoses,
damaged cylinders and bent elements.
Z Do not forget to check underneath the unit for damaged steel tubes, particularly if the unit has been
known to have operated in arduous conditions,
been grounded, or bogged down.
Z Ensure optimum operating temperature of the hydraulic oil is achieved.
Z Perform the system pressure and rear pump relief
valve pressure tests.
The above-described preliminary checks assume
that the failure is not linked to the engine performance. Having performed these checks and failed to
locate the cause of the malfunction, the following
procedures should be adopted:
Z If possible, operate the backhoe and make notes of
the operating characteristics. Cycle each control lever to operate each of the cylinders to the fully extended and retracted positions.
Z Compare the operating characteristics in the preceding stage with the malfunctions listed hereunder.
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7.2
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FAULT FINDING
GENERAL
PROBLEM
All systems fail to operate
CAUSE
Pump drive inoperative
CORRECTION
Check and repair as necessary.
Low oil level
Check and top up.
Restricted pump suction line
Inspect the suction line and the tank

and repair as necessary.
Perform pump performance test and
replace/reseal as necessary.
Slow operation or loss of power in Worn pump

all circuits
Restricted pump suction line
Load sense pressure relief valve
incorrectly adjusted
Inspect the suction line and the tank

and repair as necessary.
Make a system pressure test.
Make a system pressure test.
Hydraulic speed solenoid valve

inoperative
LOADER
PROBLEM
The lifting system fails to operate,
is slow or loses power
Bucket fails to operate, is slow or

has loss of power
Cylinder leak (spools in neutral)
Hesitation in the raising

movement of the loader
attachment or of the bucket
cylinders when the control is
initially actuated
CAUSE
Valve spool leakage
CORRECTION
Examine lift section of loader control
valve assembly for wear or scoring.
Piston seals leaking or cylinder

barrel damaged
The relief valves are stuck open,
set to a too low value or there is a
leak in the seat
Examine/reseal piston and gland.
Valve spool leakage
Examine bucket section of loader

control valve assembly for wear or
scoring.

barrel damage
Damaged piston barrel
Internal valve leakage
Examine appropriate valve section

of loader control valve assembly for
wear or scoring.
Disassemble and inspect.
Load check valve between

control valve sections damaged
Check the bucket system relief

valve.
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121
BACKHOE
Refer to the following backhoe fault finding chart after first considering the preceding charts. This chart should
only be referred to if the supply system is operating normally, thereby confirming that the hydraulic supply systems and the pump are correctly operating. See also Fault finding hydraulic pump.
PROBLEM
CAUSE
The lifting system is inoperative,

is too slow, loses power or does
not hold
Lifting system relief valve stuck

open, set too low or seat leaking
Digging system relief valve

(piston end) stuck open, set too
low or seat leaking
Valve spool leakage
The digging control fails to

operate, is slow or loses power
Test the pressure of the lifting

system relief valve.
Valve spool leakage

barrel damaged
The digging control fails to
CORRECTION
Examine lift section of backhoe

control valve assembly for wear and
scoring.
Test the pressure of the digging
system relief valve.
Examine digging section of backhoe

scoring.

barrel damaged
Bucket circuit relief valve (rod

end) stuck open, set too low, or
seat is leaking
Test the pressure of the bucket relief

valve.
Valve spool leakage

barrel damaged
The telescopic dipper fails to
The telescopic dipper system

relief valve (piston end) is stuck
open, set to a too low value or
there is a leak in the seat
Test the pressure of the telescopic

dipper relief valve.
Valve spool leakage
Examine telescopic dipper section of

backhoe control valve assembly for
wear and scoring.

barrel damaged
Stabilizer pads leaking
Examine bucket section of backhoe

scoring.
Stabilizer safety valve leaking

barrel damaged
Inspect and overhaul the stabilizer

safety valve.
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122
SWING
PROBLEM
Right or left direction swing fails
to operate, is slow, or has loss of
power
CAUSE
CORRECTION
Swing system relief valves not

seating, set too low or seat
leaking
Test the swing system relief valve.
Valve spool leakage
Examine swing section of backhoe

scoring.

barrel damaged
The swing fails to slow down
(bearing stop) at stroke end
The swing does not stop when

the control lever returns to
neutral (one direction only)
Integral sliding restrictor

damaged

barrel damage
The system relief valve (return

side) is stuck open, set to a too
low value or there is a leak in the
seat
Test the swing system relief valve.
Valve spool leakage

Cylinder leak (spools in neutral)
Internal valve leakage
Examine swing section of backhoe

scoring.
Examine appropriate valve section
of backhoe control valve assembly
for wear or scoring.

barrel damaged
A system temporarily lowers
when given the control to lift
Load check valve between

control valve sections damaged
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123
HYDRAULIC PUMP
PROBLEM
System noisy
CAUSE
Worn or damaged pump gears or
pressure plates
CORRECTION
Make a hydraulic pump performance
test.
Aeration: air entering the systems

at: suction tube, pump shaft,
fittings or cylinder ring nuts

test.
Cavitation: restrictions in the

system at the suction line or at
the suction screen in the tank
Water in the system
Hydraulic oil drain through tank

breather
The system relief valve vibrates
Visual check.
Vibrations in the lines
Check system relief valve, adjust/

overhaul as necessary.
Cold hydraulic oil
Visual check.
Wrong type oil being used
Check the hydraulic oil operating

temperature.
Tank overfilled
Investigate/drain and top up.

Check the hydraulic oil level.
Aeration: air entering the system

at: suction tube, pump shaft,
fittings or cylinder ring nuts
Cavitation: Restriction of the
suction filter in the tank
Oil heating
Make a visual check and/or a

hydraulic pump performance test.
Oil supply low

test.
Make a visual check and/or a

hydraulic pump performance test.
Fill the tank.
Contaminated oil
Drain the tank and refill with clean

oil.
Setting of relief valve too high or

too low
Drain the tank and refill with clean

oil. Test relief valves.
Oil in system too light
Drain the tank and refill with oil with

the correct viscosity.
Clean the oil cooler.
Shaft seal oil leakage
Oil cooler fins blocked

Worn shaft seal
Foaming oil
Low oil level
Replace shaft seal and inspect

pump.
Fill the tank.
Air in the suction system
Check/tighten suction line.
Wrong oil type
Drain and refill with correct oil.
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NOTES:
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580SR
580SR+
590SR
695SR
2. REMOVAL AND INSTALLATION COMPONENTS ...................................................................................... 5
2.1 COMPONENTS WITHIN THE CHASSIS .............................................................................................. 5
2.2 COMPONENTS BELOW THE CHASSIS .............................................................................................. 6
2.3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS....................................................................... 8
2.4 COMPONENTS ATTACHED ON THE CHASSIS ................................................................................. 9
2.5 MOUNTING SCREW TORQUE........................................................................................................... 11
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1.
This section can be used as a quick reference for

general disassembly of the machine and its components.
The chassis of the Backhoe Loader is manufactured
as a one piece unit on which the major assemblies
are attached or supported from.
The chassis are mainly of two kinds and differ from
one other according to the kind of backhoe attachment that the backhoe loader should carry:
Z Center pivot: means that the backhoe is connected
directly to the chassis and cannot shift laterally (only
for 4WS).
Z Sideshift: means that the backhoe is installed on the
side shift support and can shift laterally on the chassis guides.
The chassis change according to the machine steering (2WS or 4WS) because of the different wheel
shape; or because the machine can be equipped either with straight loader arm (2WS machines) or
with bent loader arm (4WS machines).
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CENTER PIVOT 4WS CHASSIS
SIDESHIFT 2WS CHASSIS
SIDESHIFT 4WS CHASSIS
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2.
REMOVAL AND INSTALLATION COMPONENTS
2.1
COMPONENTS WITHIN THE CHASSIS
ENGINE
Supported by 2 rubber silent blocks and held in position by 2 support brackets. The brackets, which
are welded to the frame one either side of the engine are positioned just ahead of the loader posts.
SWARNING
The engine and transmission bolted together act as
a one piece unit. If separated in the machine they
are not self supporting and will collapse causing injury or damage to the machine.
TORQUE CONVERTER
Fitted between the engine and the transmission can
only be removed when the engine/transmission assembly are separated.
TRANSMISSION
Attached to the rear of the engine and supported in
rubber silent blocks in fixed brackets and held within
the frame just at the rear of the loader post.
To make repairs that require disassembly of the
transmission or engine it will be necessary to remove the engine/transmission as a complete unit
from the chassis.
To remove the engine/transmission from the machine it will be necessary to remove or disconnect
the following:
Remove:
Air filter
Engine guard
Radiators and related hoses (Or pivot forward
where possible)
Front support cowling (if required)
Disconnect:
Fuel pump throttle cable and electric shut off
Engine harness
Fuel tank connection and leak off return pipes
Hydraulic pump and related pipework (plug all ports
as required)
Transmission Lever
Transmission harness connectors
Engine supports (with engine supported by hoist)
Transmission supports
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2.2
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COMPONENTS BELOW THE CHASSIS
FRONT AXLE
REAR AXLE
The front axle is attached to the underside of the

chassis by 6 through screws (2WS) or 4 through
screws (4WS).
To remove front axle from the machine:
Z Park the machine on a level ground.
Z Stop the engine, remove the key and relieve any
residual pressure in the backhoe and loader attachment systems by moving the loader and backhoe attachment control levers through all operating
position.
Z Lower the stabilizers to the ground.
Z Lower the loader bucket on the ground.
Z Using the loader bucket raise the front of the machine, high enough to remove the front wheels.
Z Place stands under the chassis, supporting appropriately the machine.
Place under the axle the appropriate supporting/
removing tool.
Z Remove the nuts on the wheels and then remove
them.
Z Disconnect the steering cylinder hoses.
Z Remove the axle swivel pin attaching bolts (4WD).
Z Disconnect the spider coupling (4WD).
Z Remove the axle bolts.
Z Remove the front axle.
The rear axle is attached to the frame at the rear of

the machine by 4 through bolts.
To remove rear axle from the machine:
Z Park the machine on a level ground.
Stop the engine, remove the key and relieve any
residual pressure in the backhoe and loader attachment systems by moving the loader and backhoe attachment control levers through all operating
position.
Z Lower the stabilizers to the ground.
Z Lower the loader bucket on the ground.
Z Using the stabilizers, raise the rear of the machine,
high enough to remove the rear wheels.
Z Place stands under the chassis, supporting appropriately the machine.
Z Remove the nuts on the wheels and then remove
them.
Z Disconnect the steering cylinder hoses (4WS).
Z Disconnect the brake system hoses.
Z Disconnect the connector of harness of the differential lock (electrically controlled version).
Z Remove axle swivel pin attaching bolts.
Z Disconnect spider coupling.
Z Remove the axle bolts.
Z Remove the rear axle.
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COUNTERWEIGHT
Counterweight: is installed under the chassis in the

front section of the machine with two bolts.
The weight of the counterweight (1): 160 kg
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2.3
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COMPONENTS ATTACHED OUTSIDE THE CHASSIS
TANKS
Attached to the chassis below the cab are the tanks
for hydraulic oil (1) mounted to the right hand side of
the machine and the fuel tank (2) mounted to the left
hand side of the machine.
Both tanks when drained of their contents can be removed from the machine by removal of the attaching pipe work and supporting bolts.
IMPORTANT: ensure all ports and pipes are
plugged or blanked off to prevent dirt ingress.
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2.4
COMPONENTS ATTACHED ON THE CHASSIS
CAB
A.
B.
S.
1.
2.
3.
4.
5.
6.
7.
Front fixing
Rear fixing
Cab skirts
Main frame
Anti-vibration
Dampener
Washer
Washer
Nut
Retaining screw
8.
9.
10.
11.
12.
13.
Washer
Cab floor
Cab support (rear)
Support
Bushing
Cab support (front)
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The cab frame is a one piece unit mounted on top of

the chassis. The mains operations that have to be
done in order to remove the cab are:
Z Remove the cab skirts (S) all around the cab.
Z Disconnect the two electrical connectors from the
main harness and engine harness.
Z Remove the two front fixing bolts (7) between the
cab floor and the cab support (13) (detail A).
Z Remove the two rear fixing bolts (7) between the
cab floor and the rear supports (10) on the main
frame (1) (detail B).
Z Disconnect the two steering cylinder hoses (left
side).
Z Disconnect the pump - power steering valve hose.
Z Disconnect the power steering valve - oil tank
hose.
Z Disconnect the load sensing valve hose.
Z Disconnect the stabilizers cables (mechanical version).
Z Disconnect the parking brake cable.
Z Disconnect the water - heater hoses (after water
discharge).
Z Disconnect the air conditioning hoses (after refrigerant drain).
Z Disconnect the transport lock cable (mechanical
version).
Z Disconnect the telescopic dipper control pedal
(mechanical version).
Z Turn the knobs and the boots of the various levers
(front and rear)
Z Lift the cab with the crane after its anchorage to lifting hook.
IMPORTANT: when lifting the cab ensure the hydraulic brake tanks are not caught and damaged on
the loader support frame.
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2.5
11
In the following table are the torques for the various assemblies that should be removed to affect repair.
IMPORTANT: always ensure prior to carrying out repairs on the machine that the vehicle parking brake is on
and the wheels are chocked.
ENGINE/TRANSMISSION
COMPONENTS
TORQUES
Engine/Transmission retaining bolts and nuts
95 Nm
Engine/Transmission bolts
95 Nm
Retaining bolts air filter-frame
25 Nm
Coolant radiator bolts to frame
95 Nm
Radiator retaining bolts to frame
95 Nm
Front cardan joint to axle
38 Nm
Front cardan joint to transmission
38 Nm
Rear cardan joint to axle
38 Nm
Rear cardan joint to transmission (Powershift)
38 Nm
Rear cardan joint to transmission (Powershuttle)
70 Nm
FRONT AND REAR AXLE

COMPONENTS
TORQUES
Front axle retaining bolts to frame (2WS)
500 Nm
Front axle retaining bolts to frame (4WS)
500 Nm
Rear axle to frame retaining bolts (2WS)
800 Nm
Rear axle to frame retaining bolts (4WS)
900 Nm
HYDRAULIC SYSTEM
COMPONENTS
TORQUES
Power steering hoses to support frame
55 Nm
Backhoe control valve to frame bolts
90 Nm
Loader control pipes clamp to frame
25 Nm
TANKS
COMPONENTS
TORQUES
Oil tank bolts
85 Nm
Fuel tank bolts
85 Nm
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12
FRONT COUNTERWEIGHT
COMPONENTS
Counterweight
TORQUES
700 Nm
LOADER
COMPONENTS
Loader control pipe bracket to frame
TORQUES
25 Nm
BACKHOE
COMPONENTS
TORQUES
Backhoe to frame hose retaining clamps
52 Nm
Boom to swing support
320 Nm
Stabilizers upper pins retaining bolt
80 Nm
Fastening pin of boom cylinder
320 Nm
Fastening pin of dipper cylinder
320 Nm
Fastening pin of bucket cylinder
320 Nm
CAB
COMPONENTS
TORQUES
Cab support
450 Nm
Front cab retaining bolts
210 Nm
Rear cab retaining bolts
180 Nm
WHEELS
COMPONENTS
TORQUES
Front/rear wheels (4WS)
700 Nm
Front wheel (2WS)
330 Nm
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580SR
580SR+
590SR
695SR

3. POWER STEERING ................................................................................................................................... 12
3.1 SPECIFICATIONS ............................................................................................................................... 13
3.2 COMPONENTS ................................................................................................................................... 15
3.4 SPECIAL TOOLS................................................................................................................................. 33
3.5 FAULT FINDING.................................................................................................................................. 33
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The steering system shows these features:

Z double acting, type steering cylinder on both 2 and
4WD axles;
Z common oil tank with the main hydraulic system;
Z a tandem gear pump located on the rear of the
transmission; both pumps are driven by a shaft running directly off the flywheel.
Oil is drawn through the common inlet port into both
pumping elements.
The front pump flow is directed to the loader and
backhoe control valves and side shift clamping system.
Rear pump flow passes through the flow divider
valve which maintains priority oil flow to the steering system with remaining flow directed for stabilizers, loader and backhoe elements.
The flow divider, located on the rear of the pump,
comprises a load sensing valve and steering system pressure relief valve.
The valve ensures a priority oil flow to the steering
system while the steering is operated, with the remaining flow directed to the stabilizer, loader and
backhoe circuits;
Z Load sensing power steering.
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STEERING SYSTEM 2WS
COMPONENTS
1.
2.
3.
4.
5.
Flow divider
Power steering
Hydraulic tank
Return manifold
Oil filter
6. By-pass valve
7. Radiator
8. Front axle
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POWER STEERING - NEUTRAL
F29379
Pump pressure
Stand-by pressure
When the steering wheel is held still, the leaf springs
return and hold the power steering spool in the neutral position.
This ensures no more oil is supplied to the steering
cylinder. The spool also traps the oil in the steering
cylinder and allows oil in the sensing lines to return
to tank therefore allowing the priority flow divider to
move to the left.
Trapped oil
Return to oil tank
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POWER STEERING - TURNING RIGHT
F29384
Pump pressure
Metered pressure
When the steering wheel is turned, the movement of
the power steering spool forms a series of passages. During right turn, oil flows through the spool
along a groove and into a passage in the housing
which leads to the metering unit. A gallery is also
lined up to allow pressure oil to flow down the sensing line to the priority flow divider.
As the metering unit is turned by the drive shaft, it directs a measured quantity of oil along another set of
passages in the spool then from these to the steering cylinder.
Return oil from the other side of the cylinder is directed through the spool to a return passage in the
housing.
Trapped oil
Return to oil tank
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2.
STEERING SYSTEM 4WS
COMPONENTS
1.
2.
3.
4.
5.
Flow divider (hydraulic pump)

Power steering
Hydraulic tank
Return manifold
Oil filter
6.
7.
8.
9.
10.
By-pass valve
Radiator
Front axle
Rear axle
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STEERING CONTROL VALVE

The steering control valve is located just above the
rear axle attached to the main chassis.
Remove the four pipes and then the 2 chassis fixing
bolts, then withdraw the valve for overhaul.
Draw a diagonal line across the complete valve
block this will assist in the correct reassembly later.
The valve consists of a central manifold block which

all input and output pipes are attached to. On each
side of this block is a solenoid valve. The solenoid
valves have two positions: both of these positions
are working positions and there is no neutral point.
Each spool is detented and therefore the solenoids
are only energized momentarily to move the spool.
On the end of each solenoid is an emergency hand
operating pin which moves the control spool without
energizing the solenoid. The switching of the steering valve is normally controlled by a microprocessor
located underneath the right hand side console.
1.
2.
3.
4.
5.
6.
Solenoid knob
Solenoid
Control spool
Block
Central block
Fixing screws
7. Piston
8. O-ring
9. O-ring
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STEERING VALVE DIAGRAM
In the position shown both spools have been moved

by solenoids (2b) and (3b). The detents on the (a)
side of the solenoid hold the spool in this position
until another solenoid is pulsed.
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T3
P3
A3
B3
A2
B2
P2
T2
F29529
The spool in valve (3) was last moved by solenoid

(3b): oil flowing in from P3 flows through the internal
galleries of the spool and exits at port A3. From
here, oil enters valve (2), whose spool was last
moved by solenoid (2b). Oil flows through port P2
and exits through port T2, cutting off flow to the rear
steering cylinder. Now the oil returns in valve (3),
entering through port B3 and flowing out through
port T3. From here, oil enters the front steering cylinder.
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The three modes of steering are as follows:

Front wheel only steering
Front and rear wheel steer
Front and rear wheel crab

The solenoids energized are shown in the table below.
These are also the pins which need to be pressed
when changing steering mode manually in an emergency.
X = Energized
O = Not Energized
3a
3b
2a
2b
2WS
2WS
4WS
CRAB
11
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3.
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POWER STEERING
The steering unit consists of a metering pump that

includes:
Z A gear wheel assembly with fixed stator (with inner
teeth) and a rotor (with outer teeth).
Z A 4 ways rotary distributor consisting of an outer
sleeve and an inner selection rotor.
The selection rotor is connected to the steering
wheel, through column, that can be of two types:

fixed or adjustable.
Z A cardan shaft, mechanically tied to gear wheel assembly and to outer sleeve, allows the movement
transmission.
Z Set of centering springs between outer sleeve and
inner rotor.
L. Left control port (steering cylinder)

R. Right control port (steering cylinder)
P. Inlet to steering pump
T. Outlet to oil tank

LS. Outlet to steering pump
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3.1
13
SPECIFICATIONS
Displacement (2WS)
125 cc/rev
Displacement (4WS)
160 cc/rev
Shock valve adjustment (2WS)
200 220 bar
Shock valve adjustment (4WS)
240 260 bar

3/4 - 16 UNF
Nm
60
7/16 - 20 UNF
Nm
20
Steering wheel nut
Nm
55
Steering motor to steering column bracket
Nm
23
Power steering end cover
Nm
30
Power steering pipe connection
Nm
45
Steering motor pipe adaptors
Nm
55
Check valve bolt
Nm
30
Shock valve (4WS)
Nm
30
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HYDRAULIC DIAGRAM
1. Power steering
2. Power steering control valve
3. Check valve
4. Anti-shock valve set at 240 260 bar

5. Anticavitation valve
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3.2
COMPONENTS
* Only with 4WS models

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Sleeve
Spool
Ball
Thread bushing
O-ring
Bearing
Ring
Cross pin
Cardan shaft
Set of springs
O-ring
Distributor plate
Rotor/stator gear
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
O-ring
End cover
Washer
Special screw
Screw
Body
Ball
Pin
Check valve
Shock absorbing valve
Ring seal
Seat
15
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3.3
Copyright
DISASSEMBLY
To gain access to the power steering, remove the
hood and the air filter.
Removing power steering

Disconnect the four connectors and collect the Oring seals, noting the connector positions.
Remove the four screws from within the cab.

The power steering can be removed from the front of
the cab through the engine compartment. Place the
steering unit in the holding tool.
Screw off the screws (18), the special screw (17)

and the washers (16) from the end cover (15).
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Remove the end cover (15).
Extract the rotor/stator gear (13) (with spacer, if fitted). Extract the two O-rings (14).
Remove the cardan shaft (9).
Remove the distributor plate (12).
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Screw out the threaded bush (4) over the check

valve.
Shake out the check valve ball (3) and the suction
valve pins (21) and the balls (20). Replace the pins
(21) prior to the reassembly.
Take care to keep the cross pin in the sleeve and

spool horizontal. The pin can be seen through the
open end of the spool. Press the spool (2) inwards
and the sleeve, the ring, the races and the needle
bearing will be pushed together out of the housing.
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Extract the ring (7), the races and the bearing (6)
from the sleeve and the spool. The outer (thin) bearing race can sometimes stick in the housing, therefore check that is has come out.
Press out the cross pin (8). Use the special screw
(17). A small mark has been made with a pumice
stone on both spool and sleeve close to one of the
slots for the neutral position springs (see drawing). If
the mark is not visible, remember to leave a mark of
your own on sleeve and spool before the neutral position springs are dismantled.
Carefully press the spool (2) out of the sleeve (1).
Press the springs (10) out of their slots in the spool.
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Remove the seal ring (24) and the O-ring (5).
Remove the plugs from the shock valves using a 6

mm hexagon socket spanner.
Remove the seal washers.
Unscrew the setting screws using a 6 mm hexagon

socket spanner.
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Shake out the two springs and two valve balls into
your hand. The valve seats are bonded into the
housing and cannot be removed.
The shock valves (23) are now dismantled.
CLEANING
Clean all parts carefully.
INSPECTION AND REPLACEMENT
Check for signs of wear in the following areas:
Z Rotor and stator of metering unit move freely.
Z Check the drive pin is not cracked or bent.
Z Check the rollers in thrust bearing are free to rotate.
Z Ensure thrust washers are not warped or cracked.
Z Ensure check valve ball is free to move.
Z Check control valve, spool and sleeve for wear or
scoring.
Z Replace all seals and O-ring.
LUBRICATION
Before assembly, lubricate all parts with hydraulic
oil.
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ASSEMBLY
NOTE: great care should be taken during re-assembly.
Place the two flat neutral position springs in the slot.
Place the curved springs between the flat ones and
press them into place.
Line up the spring set (10).
Guide the spool (2) into the sleeve (1). Make sure
that spool and sleeve are placed correctly in relation
to each other.
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Assemble spool and sleeve.

When assembling spool and sleeve only one of two
possible ways of positioning the spring slots is correct. There are three slots in the spool and three
holes in the sleeve in the end of the spool/sleeve opposite to the end with spring slots. Place the slots
and holes opposite each other so that parts of the
holes in the sleeve are visible through the slots in the
spool.
Press the springs together and push them into the

sleeve.
Line up the springs and centre them.
Guide the ring (7) down over the sleeve.

NOTE: the ring should be able to move - free of
springs.
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Fit the cross pin (8) into the spool/sleeve.
Fit bearing races and needle bearings (6) as shown

on the next drawing.
1. Spool
2. Sleeve
6. Bearing - needle
6A. Outer bearing race
6B. Needle bearing
6C. Inner bearing race
The inside chamfer on the inner bearing race must
face the inner spool.
Turn the steering unit until the bore is horizontal.

Guide the outer part of the assembly tool into the
bore for the spool/sleeve.
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Grease the O-ring (5) with hydraulic oil and install it

on the attachment.
Hold the outer part of the assembly tool in the bottom

of the steering unit housing and guide the inner part
of the tool right to the bottom.
Press and turn the O-ring into position in the housing.
Draw the inner and outer parts of the assembly tool

out of the steering unit bore, leaving the guide from
the inner part in the bore.
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Lubricate the seal ring (24) with hydraulic oil and

place it on the assembly tool.
Guide the assembly tool right to the bottom.
Press and turn the seal ring into the housing.
With a light turning movement, guide the spool and

sleeve into the bore.
Fit the spool set holding the cross pin horizontal.
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The spool set will push out the assembly tool guide.
The O-ring is now in position.
Turn the steering unit until the bore is vertical again.

Put the check valve ball (3) into the hole indicated in
the picture.
Screw the threaded bush (4) lightly into the check

valve bore. The top of the bush must lie just below
the surface of the housing.
Place a ball (20) in the two holes indicated in the picture.
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Insert the pins (21) into the same two holes.
Grease the O-ring (11) with mineral oil.
Position the distributor plate (12) so that the channel

holes match the holes in the housing.
Guide the cardan shaft (9) down into the bore so that
the slot is parallel with the connection flange.
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Place the cardan shaft (9) as shown - so that it is

held in position by the mounting fork.
Grease the two O-rings and place them in the two

grooves in the gear rim. Insert the rotor/stator gear
and the rim on the cardan shaft.
Fit the gearwheel (rotor) and cardan shaft so that a

tooth base in the rotor is positioned in relation to the
shaft slot as shown. Turn the gear so that the seven
through holes match the holes in the housing.
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For precise keying and alignment of steering control

valve, pay attention to the parallelism of (A), (B), (C)
and (D) reference marks.
A.
B.
C.
D.
E.
F.
Rotor/stator surface
Distributor plate surface
Pin axis
Housing surface
Rotor gear
Cardan shaft
Position the end cover (15).
Assemble the special screw (17) with the washer

(16).
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Fit the 6 screws (18) with the relevant washers (16).

Cross-tighten all the screws and the roller pin to a
torque of 30 6 Nm in the sequence shown. The initial torque is 10.8 Nm.
Put a ball in the two holes.
Place springs and valve cones over the two balls.
Screw in the two setting screws.
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Screw plug with seal ring into the two shock valves
and tighten them with a torque of 30 10 Nm.
Position the seal ring (24) into the housing.
Install the seal ring into the housing using the special
tool and a plastic hammer.
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3.4
SPECIAL TOOLS
P/N CNH
3.5
33
DESCRIPTION
380000281
Assembly tool for seal ring.
380002677
Assembly tool for ring.
380002679
Assembly tool for cardan shaft.
380002680
Assembly tool for O-ring.
FAULT FINDING
PROBLEM
No steering or excessive effort

required to steer
CAUSE
Incorrect oil level in tank
Air in system
Pump relief valve faulty
Worn pump
Leaking power cylinder
Damaged valve spool
Broken or damaged steering column
Damaged or worn metering element
Steering wanders
CORRECTION
Fill with the correct oil type and
quantity.
Check for loose connections or damaged lines.
Bleed the system.
Check the system pressure.
Inspect and repair.
Inspect and repair.
Inspect and replace.
Excessive clearance in the ball

joints of the steering connecting
rods
Control valve spool sticking or
worn
Front wheels surge when steering

Control valve spool sticking
Inspect and repair.

Inspect and repair.
Noisy pump
Incorrect oil level in tank
Fill with the correct oil type and

quantity.
Air in system
Check for loose connections or damaged lines. Drain the oil from the
system.
Drain and change the oil.
Replace the pump.
Water in oil
Worn pump
Inspect and repair.

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NOTES:
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580SR
580SR+
590SR
695SR
SECTION 50 - CAB HEATING AND AIR

CONDITIONING
1. SPECIFICATIONS ........................................................................................................................................ 3
2. CAB HEATING.............................................................................................................................................. 5
3. AIR CONDITIONING .................................................................................................................................. 12
3.1 PRINCIPALS OF AIR CONDITIONING ............................................................................................... 12
3.2 SAFETY PRECAUTIONS .................................................................................................................... 16
3.3 CONTROLS AND OPERATION .......................................................................................................... 17
3.4 FAULT FINDING AND TESTING......................................................................................................... 26
3.5 FLUSHING THE SYSTEM................................................................................................................... 44
3.6 EVACUATING THE SYSTEM.............................................................................................................. 46
3.7 CHARGING THE SYSTEM.................................................................................................................. 47
3.8 COMPONENTS OVERHAUL .............................................................................................................. 48
3.9 COMPRESSOR ................................................................................................................................... 53
3.10 SPECIAL TOOLS............................................................................................................................... 67
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1.
SPECIFICATIONS
HEATING
ENGINE RADIATOR COOLANT

Antifreeze - Ambra Agriflu
12 litres
Water
12 litres
System type
Pressurized FULL FLOW by-pass with

expansion chamber
FAN BELT DEFLECTION

Naturally aspired
13 - 19 mm
Turbocharged
10 - 16 mm
THERMOSTAT
Start to open at
82 C
Fully open at
95 C
Radiator cap
0.90 bar
TORQUE VALUES
Coolant/hot water hose connections
5 Nm
Air hose ducting connections
5 Nm
Heater housing to floor mounting bolts
6.2 Nm
Refrigerant
HFC 134a
Refrigerant charge
1.2 kg
Compressor oil
SP20 (PAG Type, Viscosity index 100)
Oil change amount
135 cc
CHECK CONDITIONS
Air inlet temperature
37.8 C
Rated air inlet moisture
40%
Evaporation temperature
0 C
Overheating
5 C
Inlet air speed
1.0 - 2.0 - 3.0 m/s
Condensation temperature
58 C (absolute 16 bar)
Undercooling
2 C
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PERFORMANCE CALCULATED AT m/s (191.72 m3/h)

Exchanged warmth
5.48 kW
4718.28 kcal/h
Air outlet temperature
5.64 C
Air side load loss
2.97 daPa
0.30 mmH20
Coolant side load loss
13.1 kPa
0.13 bar
Exchanged warmth
9.29 kW
7998.69 kcal/h
10.30 C
Air side load loss
9.34 daPa
0.95 mmH20
32.7 kPa
0.33 bar
Exchanged warmth
12.00 kW
10332.00 kcal/h
13.70 C
Air side load loss
18.30 daPa
1.87 mmH20
51.20 kPa
0.51 bar
PERFORMANCE CALCULATED AT 2.0 m/s (383.4 m3/h)
PERFORMANCE CALCULATED AT 3.0 m/s (575.1 m3/h)
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2.
CAB HEATING
2.1
Cab heating
The cab is heated by a radiator mounted below the
cab seat, which is supplied hot water from the engine
coolant system. A blower motor mounted behind the
cab radiator is used to transfer the heat into the cab.
Heater blower control
The three speed blower is controlled by switch (1)
mounted in the instrument console to the right of the
cab seat. Turn the switch clockwise to the first position for slow speed. Further rotation of the switch in
a clockwise direction selects medium and fast
speeds. The blower draws outside air from beneath
the cab floor and through a filter medium into the
cab.
Temperature control
The temperature of the air from the radiator is adjusted by rotation of the control knob (2) which opens or
closes the radiator valve increasing or decreasing
the water flow as required. Turn the control clockwise to increase the temperature of air from the
heater and counter clockwise to reduce the temperature.
S WARNING
The cab air filters are designed to remove dust from
the air but may not exclude chemical vapour. When
working in an enclosed area ensure there is adequate ventilation as exhaust fumes can suffocate
you.
Cab air filter
Before servicing the air filter situated under the drivers seat, switch off the blower and close all windows
and one door. Forcibly close the other door. The resulting back pressure will dislodge loose dirt from
the underside of the filters. To remove the filter (3)
release the retaining straps (4) and remove the filter
element. Ensure the element, and sealing faces are
not damaged on removal.
IMPORTANT: in humid conditions, such as occur on
most early mornings, do not switch on the blower prior to servicing the filters. Damp particles drawn into
the filter may solidify and prove difficult to remove
without washing.
The filter element is made of specially treated paper
with a sealing strip bonded to the outer face.
Clean this element by blowing with compressed air
from the clean side through to the dirty side. The
compressed air should not exceed 2 bar and the air
line nozzle should be at least 300 mm from the element.
4
F29325
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Heater radiator
The heater radiator (1) is fitted in a housing under
the cab seat for central displacement of warm or cold
air flow.
IMPORTANT: to ensure a good flow of air through
the heater radiator the filter should be cleaned more
frequently when operating in extremely dusty conditions.
Air flow vents

Air flow vents are connected to the heater container
and receive air from the blower motor, to direct warm
or cold air onto the windscreen and side windows or
to the cab interior as required.
Each vent may be swivelled and adjusted to control
the flow of air.
To open a vent, press one side of the disc and turn
it, as required, to direct the air flow.
The vents are located as follows:
- two on the top of the front control panels (A);
- two to the rear of the seat (C);
- two under the seat, one in front, the other on the
rear (D);
- two on the cab posts, right and left (B);
- two on the ceiling, in front and back of operators
head (E).
NOTE: the vents (B) and (E) are mounted only when
air conditioning (optional) is fitted.
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F30058
Schematic - Heater system

1. Heater valve mounted to the right of the heater
housing
2. Air ducting to the front windscreen
3. Radiator hoses of the heater control panel
4. Air ducting to the rear windscreen below the cab
floor
5. Air intake to the heater housing from below the

cab floor
6. Heater pipes to and from heater taken from the
engine oil
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Electrical heater valve

The electrical valve is equipped with a software that,
each time the supply of the cock is delayed (therefore also at backhoe loader start), carries out the momentary positioning of the cock to completely
closed and returns to the position set by the temperature regulation handle located on the control dashboard. This enables the software to carry out a selfcontrol on the cock drive so as to always obtain an
optimal regulation of the ball for the water flow.
This is part of the cock normal operation and is not to
be considered as a fault.
Release of the electrical heater valve
IMPORTANT: the release of the valve has to be performed if this valve remains idle for long periods.
Carry out this operation observing the following procedure:
Z Disconnect the electrical connectors (1).
Z Loosen the screws (2) and take out the electrical
valve (3) from the evaporator.
Z Loosen and remove the screws (4).
3
4
1
F30059
Z Separate the driving unit (5) from the cock (6).

Z By means of a wrench turn pin (A) of the cock so as
to unlock it.
S WARNING
Once this operation is complete, reset pin (A) in the

correct start position.
Reinstall the heater valve, repeating the previous
operation in the reverse order.
6
A
F30060
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FAULT FINDING -GENERAL

Items that may cause a concern are suggested in
the fault finding chart but as a general rule apply the
following steps:
Ensure water flow to the heater radiator is steady
and all air has been removed from the system.
Hoses are unrestricted and not leaking.

Check the electrical connections are good and the
blower motor is operational.
The operating cable to the heater valve and valve is
operational.
FAULT FINDING
PROBLEM
Dust enters the cab
CAUSE
CORRECTION
Improper seal around filter element
Check the seal condition.
Blocked filter
Clean or replace the filter.
Defective filter
Replace the filter.
Excessive air leak (s) around doors

and windows
Repair and Seal air leak(s).
Blocked filter or recirculation filter
Clean or replace the filter(s).
Heater radiator core blocked
Clean radiator core thoroughly.
Blower motor not working
Fuse blown
Replace fuse.
Cab does not heat up
Engine not reaching operating temperature.

Thermostat stuck open
Replace the temperature switch.
Blower motor air flow low
Heater hose from engine to cab radi- Ensure water flow to heater radiator
ator, kinked or blocked
is adequate and not restricted.
Cab does not cool
Temperature not stable
Heater control turned on
Turn the temperature control knob

fully counterclockwise for maximum
cooling.
Heater control valve stuck in open

position
Free up valve or change as required.
Low engine coolant
Top up coolant recovery tank.
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OVERHAUL
IMPORTANT: when overhauling the heating system
remember that, with the engine running or shortly after it is turned off, the system will be at engine temperature and therefore the water will be hot and
under pressure.
To effect repairs to the heater core or blower motor,
it will be necessary to remove the attaching bolts (1)
from the seat and remove seat from the heater housing.
Draining the system
To drain the cooling system down disconnect either
hose at the T junction (2) found at the rear of the engine oil filter mounted to the left hand side of the engine.
F28674
Heater radiator
With the system drained remove the heater radiator
hose connections, attaching bolts and remove from
the vehicle.
Inspect the heater radiator (3).
Check water flow through the heater pipe which
should be free running; if not, clear any blockage.
Fins should be free of all debris and not damaged;
clean and or repair.
Clean the heater radiator using compressed air not
exceeding 7 bar taking care not to damage the radiator fins.
Ensure the radiator is not leaking under pressure;
repair or replace as required.
Clean the chamber with a damp, cloth and re-assemble the housing filter element with the seal facing the inside of the cover.
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11
Blower motor
The blower motor (1) can be removed by removal of
the attaching hardware and disconnection of the wiring connector.
Check the blower is working, if not check fuse and
continuity of blower motor. If defective replace the
blower unit as an assembly.
Heater control valve

To service the control valve (2) disconnect the hoses
and the control cable and remove. Check the operation of the valve and if tight or worn replace.
Heater control panel

The blower motor is operated by a 3 position switch
(3) which through a variable potentiometer increases or decreases voltage to the blower motor.
The heater valve is operated by a control cable
which will push or pull the valve into an open or
closed position.
Both of the above are mounted to the right of the

drivers seat and can be accessed by removal of the
control panel for repair or replacement.
F28679
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3.
AIR CONDITIONING
3.1
PRINCIPALS OF AIR CONDITIONING
The function of the air conditioning system is to improve the operators comfort by cooling the air temperature inside the cab and reducing the humidity
level. In order to achieve this heat transfer the following principals of heat generation and transfer are applied within the air conditioning system.
1. When two bodies of different temperature come
together heat is transferred from one to another.
On air conditioning systems an evaporator is
used to hold the low temperature refrigerant
which absorbs the heat from the air within the
cab.
F28680
2. When a gas is pressurized the temperature of

the gas will rise. In air conditioning systems the
increase in pressure is achieved using a compressor.
F28681
3. When a gas is cooled it will condense into a liquid. In the air conditioning system a condenser is
used to cool the gas and the resulting liquid is
stored in a receiver dryer.
F28682
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4. When a liquid is atomized through an orifice, the

temperature of the resultant vapour will lower.
The low temperature of the atomized liquid will
then absorb heat from its surrounding. On air
conditioning systems the refrigerant is atomized
using an expansion valve.
C?
F28683
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Air conditioning principle of operation

1. Expansion valve-atomizes liquid refrigerant before passing to evaporator
2. Evaporator-absorbs heat from air in cab
3. Compressor-compresses and raises temperature of refrigerant gas

4. Condenser and receiver dryer-converts refrigerant from gas to a liquid
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LOW PRESSURE SIDE
15
HIGH PRESSURE SIDE
EXPANSION
VALVE
LOW
TEMPERATURE
HIGH PRESSURE
LIQUID FILTERED
AND MOISTURE
REMOVED
LIQUID ATOMIZED
AT A LOWER
TEMPERATURE
RECEIVER
DRYER
LOWER
TEMPERATURE
HIGH PRESSURE
LIQUID
EVAPORATOR
CONDENSER
WARM LOW
PRESSURE VAPOUR
HIGH
TEMPERATURE
HIGH PRESSURE
VAPOUR
COMPRESSOR
HEAT FROM INSIDE
CAB MOVES TO
REFRIGERANT
HEAT MOVES TO
OUTSIDE AIR FROM
REFRIGERANT
Air conditioning flow diagram

It can now be seen that the principal components of
an air conditioning system are:
Z Refrigerant
Z Compressor
Z Condenser
Z Receiver dryer
Z Expansion valve
Z Evaporator
The figure in the previous page uses the examples
above to illustrate the air conditioning cycle.
The figure in the this page shows in schematic form

the flow of refrigerant through the five major components of an air conditioning system.
Refrigerant is drawn into the compressor as a cool,
low pressure vapour which is compressed and then
pumped out as a hot, high pressure vapour to the
condenser.
As the hot, high pressure vapour passes through the
condenser core it gives off heat to the cooler outside
air, being drawn past the fins by the engine cooling
fan.
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By giving off heat to the outside air, the vapour is

condensed to a liquid which moves under high pressure to the receiver dryer where it is stored until released to the evaporator by the temperature
sensing expansion valve.
As liquid refrigerant passes through the metered orifice in the expansion valve the refrigerant changes
from a high pressure liquid to a low pressure atomized liquid with a lower temperature.
This low pressure, low temperature, atomized liquid
enters the evaporator coils and absorbs heat from
3.2
the cab warm air blown across the coils and fins by
the cab blower motor. The refrigerant now changes
from a cold low pressure atomized liquid to a warm
low pressure vapour and leaves the evaporator outlet, moving to the suction (low pressure) side of the
compressor to repeat the cycle.
As this heat loss is taking place, moisture (humidity)
in the cab air will condense on the outside of the
evaporator and drain off as water through the drain
hoses attached to the evaporator drain pan, thereby
reducing the humidity level of the cab.
SAFETY PRECAUTIONS
S WARNING
Before overhauling an air conditioning system read
and observe the following safety precautions. If a repair or replacement becomes necessary, ensure
that only certified air conditioning technicians are
employed, using approved equipment to effect repairs.
Do not attempt to disassemble the air conditioning
system. It is possible to be severely frostbitten or injured by escaping refrigerant.
IMPORTANT: do not allow refrigerant to escape
into the atmosphere.
Refrigerant must be handled with care in order to
AVOID HAZARDS.
Undue direct contact with liquid refrigerant can produce freezing of skin and eyes.
Keep the refrigerant container and air conditioning
system away from flame or heat sources; the resulting pressure increase can cause the container or
system to explode.
If in direct contact with open flames or heated metal
surfaces, the refrigerant will decompose and produce products that are toxic and acidic.
Make sure to comply with the following indications

and simple precautions to avoid any risk of injury:
Z Never discharge refrigerant into the atmosphere.
When servicing air conditioning units a certified refrigerant recovery unit operated by a certified technician must be used.
Z When discharging the refrigerant in the system
make sure you are operating in well-ventilated
premises with good air circulation and far away
from open flames.
Z When charging and discharging the system always
wear goggles and take suitable precautions to protect the face in general and the eyes in particular,
from accidental spillage of the refrigerant fluid.
Z The oil and refrigerant mixture inside the air conditioning system is pressurized. Consequently, never loosen fittings or tamper with lines unless the
system has been properly discharged.
Z Before loosening any connection, cover the fitting
in question with a cloth and wear gloves and goggles in order to prevent refrigerant from reaching
the skin or eyes.
Z In the event of an accident, proceed as follows:
If the refrigerant has reached the eyes, wash them
immediately with copious amounts of sterilized water or mains pressure tap water and transfer to
hospital for immediate medical help.
If the refrigerant has touched the skin, wash with
cold water and transfer to hospital for immediate
medical help.
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3.3
17
CONTROLS AND OPERATION
CONTROLS (580SR)
The air conditioning control can be adjusted to obtain
the desired temperature in the cab.
To activate air conditioning, turn the selector (2).
Upon activation, the warning lamp (3) turns on. The
selector (1) allows choosing the ideal temperature
according to your requirements. Positioning selector
(1) to 0 and turning selector (2) you will obtain more
or less cold according to the selector (2) position. By
positioning selector (1) to any other position different
from 0, you will obtain instead a mixture of warm
and cold air and the desired climate inside the cab.
NOTE: the air conditioning can be operated only if
the ventilation selector (4) is not set to the stop position.
Turn the selector (4) for air capacity according to

your requirements.
CONTROLS (580SR+ / 590SR / 695SR)
The air conditioning control can be adjusted to obtain
the desired temperature in the cab.
To activate air conditioning, turn the selector (2).
Upon activation, the warning lamp (4) on the side instrument cluster turns on. The selector (1) allows
choosing the ideal temperature according to your requirements. Positioning selector (1) to 0 and turning selector (2) you will obtain more or less cold
according to the selector (2) position. By positioning
selector (1) to any other position different from 0,
you will obtain instead a mixture of warm and cold air
and the desired climate inside the cab.
2
NOTE: the air conditioning can be operated only if
the ventilation selector (3) is not set to the stop position.
Turn the selector (3) for air capacity according to
your requirements.
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OPERATION
IMPORTANT: when using the air conditioning, it is
essential that all the windows of the operators compartment are completely closed.
NOTE: to ensure correct operation and full efficiency
of the air conditioning system, it must be used at
least once a week, even for a short time.
The air-conditioner filter is located on the left hand
side of the seat pod.
S WARNING
The air filter is designed to remove dust from the air
but may not exclude chemical vapour. Refer to
chemical manufacturers directions regarding protection from dangerous chemicals.
If the machine has been parked in the sun, quicken
the cooling by operating the air-conditioning for 2-3
minutes at its coldest setting. Set maximum blower
speed with a window left partially open to force most
of the warm air from the cab.
With the air cooled sufficiently, close the window and
adjust the controls to the desired temperature. To
ensure proper operation of the system be sure the
cab filter is regularly serviced. Refer to filter maintenance.
It is the normal function of the air-conditioner to extract water from the air. As such it is possible pools
of water will collect beneath the drain hose outlets
under the cab when the machine is stationary.
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19
COOLANT
To achieve the absorption and the release of heat
which is, in essence, the function of an air conditioning system, requires the use of a suitable refrigerant a liquid that has a relatively low temperature
boiling point, plus certain desirable safety and stability features.
The refrigerant used in the air conditioning system is
refrigerant HFC 134a.
NOTE: to help protect the environment legislation
has been introduced in most territories banning the
release into the atmosphere of refrigerants, including HFC 134a. All service procedures contained in
this manual can be carried out without the need to
release refrigerant into the atmosphere.
In order to prevent the incorrect type of refrigerant
being charged to the system the service valves fitted
to the Backhoe Loader and necessary to connect up
refrigerant recovery, evacuation and recycling/recharging equipment will be of two different sizes as
recognized and specified by the air conditioning industry.
S WARNING
Coolant HFC 134a is not compatible with coolant
R-12. Do not try to replace coolant HFC 134a with
coolant R-12 or to test the system using instruments
or attachments previously used with R12, as the
system could get damaged.
HFC 134a refrigerant is stable at all operating temperatures and able to absorb great quantities of
heat.
The boiling point of HFC 134a is -22 C at atmospheric pressure.
If the pressure is increased, HFC 134a will readily
vaporize to absorb heat at temperatures between 11.7 C at 1.9 bar and 0 C at 2.9 bar in the evaporator.
At higher pressures, HFC 134a will condense and
give off heat at temperatures between 48 C at
12.4 bar and 58 C at 15.85 bar in the condenser.
S WARNING
HFC 134a can be dangerous if improperly handled.
Therefore it is important the following warning and
directions are adhered to.
Never expose any part of the air-conditioner system
to flame or excessive heat because of risk of fire or
explosion, and the production of phosgene gas.
Never disconnect or disassemble any part of the airconditioning system as escaping refrigerant can
cause frostbite.
S WARNING
If refrigerant should contact the skin use the same
treatment as for frostbite.
Warm the area with your hand or lukewarm water
32 C, cover the area loosely with a bandage to
protect affected area against infection and consult
a doctor immediately.
If refrigerant should contact the eyes wash immediately in cold clean water for at least 5 minutes
and consult a doctor immediately.
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COMPRESSOR
The air conditioning compressor is mounted on the
left hand side of the engine and is belt driven from
the crankshaft pulley.
The compressor separates the low and high pressure sides of the system and has two functions:
1. To raise the refrigerant temperature by compression to a higher degree of temperature than
the ambient (outside air) temperature.
2. To circulate the required volume of refrigerant
through the system.
The refrigerant compressor is a seven cylinder wobble plate unit housed in a die cast aluminium housing.
Drive to the wobble plate is from the pulley, through
the electro-magnetic clutch to the main driveshaft.
Attached to the driveshaft is a cam rotor which oscillates the wobble plate. The wobble plate is prevented from rotating by a static gear engaging with teeth
formed in the face of the plate. The seven pistons are
connected to the wobble plate by rods located in ball
sockets.
Refrigerant is drawn in on the downward stroke of a
piston through the reed valves located either end of
the cylinder assembly. Refrigerant enters the cylinder assembly through a gallery in the outer circumference of the cylinder assembly.
During the upward stroke, the piston compresses the
refrigerant and expels it through another reed valve
into an inner gallery in the cylinder and, from here,
out into the coolant system.
The compressor is lubricated with a Polyalklene Glycol (PAG) oil Type SP20. This oil can be mixed with
coolant and is carried around in the coolant system
itself.
The compressor is activated by an electro-magnetic
clutch which functions to engage or disengage the
compressor as required in the operation of the air
conditioning system.
The clutch is primarily activated by the:
Z temperature control
Z low pressure cut-out switch
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Temperature control
The air conditioner temperature control switch is
mounted on the blower motor assembly.
The switch is a device which turns the compressor
clutch on and off to maintain a constant average
evaporator temperature and senses the evaporator
temperature using a thermistor (1).
The temperature control switch compares the voltage of the thermistor, which is dependent on the
temperature of the evaporator, with the voltage
across the potentiometer of the in cab temperature
control switch.
The switch upon comparing the two voltages determines whether the compressor clutch should be
switched on or off in order to maintain the desired
in cab temperature control.
Low pressure cut-out switch
The low pressure switch (1) is mounted in the top of
the filter (2) mounted in front of the radiator behind
the battery.
The purpose of the switch is to shut off the compressor pump in the event of low pressure in the refrigerant system.
Low refrigerant pressure may occur due to a faulty
expansion valve, icing up of the expansion valve orifice or refrigerant loss. Low refrigerant pressure
may result in damage to the compressor pump.
The low pressure switch is factory set and cannot be
adjusted.
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CONDENSER
The condenser (1), located at the front of the machine in front of the engine radiator consists of a
number of turns of continuous coil mounted in a series of thin cooling fins to provide a maximum of heat
transfer in a minimum amount of space.
NOTE: the condenser after removal of the attaching
bolts can be slid out for cleaning.
The condenser receives the hot, high pressure refrigerant vapour from the compressor. The hot vapour passes through the condenser coils and
outside air is drawn through the condenser by the
engine cooling fan.
Heat moves from the hot refrigerant vapour into the
cooler outside air flowing across the condenser coils
and fins.
When the refrigerant vapour reaches the pressure
and temperature that will induce a change of state, a
large quantity of heat is transferred to the outside air
and the refrigerant changes to a high pressure warm
liquid.
The warm liquid refrigerant continues onto the receiver/drier where it is filtered and desiccated, to remove any moisture, before passing through an
outlet line to the thermostatic expansion valve.
RECEIVER DRYER
The receiver/dryer (2) situated behind the battery
stores the liquid refrigerant to be sure a steady flow
to the thermostatic expansion valve is maintained
under widely different operating conditions.
The drier section contains a desiccant (Molecular
sieve) to absorb any moisture within the system and
a filter prevents the entry of foreign particles.
NOTE: any moisture in the air conditioning system is
extremely harmful. Moisture not absorbed by the dehydrator will circulate with the refrigerant and droplets may collect and freeze in the thermostatic
expansion valve orifice. This action will block the refrigerant flow and stop the cooling action. Moisture
will also react with refrigerant HFC 134a and the lubricant to form a corrosive acid.
The desiccant can only absorb a limited amount of
moisture before reaching saturation point. Because
of this, after any system component replacement or
repairs requiring entry into the system, the receiver/
dryer should be replaced.
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EXPANSION VALVE
The expansion valve is located underneath the
evaporator in the pressure line leading from the receiver/dryer and performs the following functions:
1. METERING ACTION
A metered orifice changes the liquid refrigerant
from a high pressure low temperature liquid to a
low pressure, lower temperature atomized liquid.
2. MODULATING ACTION
A thermostatically controlled valve within the expansion valve body controls the volume of liquid
refrigerant passing through the orifice and
makes sure the refrigerant is fully vaporized
within the evaporator. Liquid refrigerant at would
damage the compressor reed valves or freeze
the pistons.
3. CONTROLLING ACTION
The valve responds to changes in the cooling requirements. When increased cooling is required,
the valve opens to increase the refrigerant flow
and when less cooling is required the valve closes and decreases the refrigerant flow.
Expansion valve - operation
All of the needed temperature sensing and pressure
sensing functions are consolidated into this basic unit
and no external tubes are required for these purposes.
The refrigerant from the condenser and receiver dryer enters the thermostatic expansion valve as a high
pressure warm liquid. Upon passing through the ball
and spring controlled metering orifice, the pressure
and temperature of the refrigerant is reduced and
the refrigerant leaves the thermostatic expansion
valve as a low pressure, lower temperature atomized liquid.
The atomized liquid now passes through the evaporator where it absorbs heat before returning via the
expansion valve to the compressor as a warm low
pressure vapour. There are two refrigerant passages in the valve. One passage is in the refrigerant line
from the condenser to the evaporator and contains
the ball and spring type orifice valve.
The other passage is in the refrigerant line from the
evaporator to the compressor and contains the
valves temperature sensing element.
Liquid refrigerant flow from the condenser and receiver dryer is controlled by a push-rod forcing the
orifice valve ball off its seat and the spring exerting
pressure on the ball to keep it on its seat.
During stabilized (vehicle shutdown) conditions, the
pressure on the bottom of the expansion valve diaphragm rises above the pressure on the top of the diaphragm allowing the valve spring to close the
orifice.
F28691
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When the system is started, the pressure on the bottom of the diaphragm lowers rapidly, allowing the orifice to open and metre atomized liquid refrigerant to
the evaporator where it begins to vaporize.
Suction from the compressor draws the vaporized
refrigerant out of the evaporator and back through a
gallery in the top of the valve which asses the temperature sensor.
The temperature sensor reacts to variations in refrigerant gas pressure returning from the evaporator.
When heat from the passenger compartment is absorbed by the refrigerant the pressure of the gas increases causing a differential pressure above and
below the temperature sensor diaphragm. The diaphragm reacts to this pressure differential and a
push rod forces the ball in the expansion valve orifice
further off its seat. This reaction allows an increase
in the atomized refrigerant to flow through the valve,
to the evaporator, so that more heat can be absorbed
by the air conditioning system.
Similarly when the temperature of the gas returning
from the evaporator decreases the pressure of the
gas decreases. This causes the diaphragm to react
accordingly and allow the ball in the orifice to move
closer towards its seat thus reducing the flow of refrigerant through the valve to the evaporator.
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EVAPORATOR
The evaporator is located beneath the cab seat and
consists of a number of turns of continuous coils
mounted in a series of thin cooling fins to provide a
maximum of heat transfer in a minimum amount of
space.
Low temperature refrigerant in the evaporator absorbs heat from the hotter air in the operators compartment, thereby cooling the air.
Air Recirculation
An intake grille is located on the left side of the seat
base. A portion of the air flow will recirculate through
the evaporator.
Filter General
The blower fan, draws warm air from outside the cab
through the intake filter (2) below the cab floor and a
ready cooled dehumidified air through the recirculation grille (1). The air passes over the evaporator
then into the cab through the six louvered vents.
Two vents are located on the front instrument panel
to direct air onto the windshield. Two are located at
the base of the rear posts to direct air onto the rear
window. Two additional vents are located at the front
and rear of the seat base to direct air at the operators feet.
1
F29327
Blower Fan
The blower motor is controlled by a three-speed
switch (3) which uses a variable resistor to change
the fan speed.
High blower speed provides the greatest volume of
circulated air, however, a slower speed will allow the
air to contact the cooling fins and coils of the evaporator for a longer period resulting in the warm air giving up more heat to the cooler refrigerant. Therefore,
the coldest air temperature is obtained when the
blower fan is operated at the lowest speed.
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FAULT FINDING AND TESTING
Overhaul of the air conditioning system should only

be undertaken by a certified specialist refrigeration
engineer using a comprehensive air conditioning
test kit, including a gas leak detector, suitable for
HFC 134a refrigerant gas.
S WARNING
Before dismantling an air conditioning system for repair the gas within the system must be discharged
and recovered using a certified recovery unit designed for the type of refrigerant gas used in the system.
NEVER release refrigerant gas into the atmosphere.
ALWAYS wear safety goggles and gloves when
servicing any part of the air conditioning system.
To prevent the entry of any foreign material, observe
the following points:
Z Ensure all tools, gauges, hoses and replacement
parts are kept clean and dry and are suitable for
the type of refrigerant gas used in the system.
Z Clean all hoses and fittings before disconnecting.
Z Cap or plug all openings when disconnected.
Z When adding lubricating oil to the system always
uncap and re-cap the oil container immediately before and after use. Always ensure the oil remains
free of moisture.
Preliminary fault finding

Always conduct the preliminary fault finding checks
before performance testing the system.
1. Run the engine at 1000-1200 rpm for 10 minutes with the air conditioner set to maximum
cooling and the blower at high speed.
2. Check that the heater temperature control is
switched OFF.
3. Check that the blower fan is operating at all
speeds.
4. Check that the compressor clutch engages
when the temperature control switch is turned
from OFF to ON position. A clicking sound indicates the clutch is engaging. If the clutch fails to
operate it may indicate an electrical problem in
the high low pressure cut out switches or malfunction of the electrical drive clutch on the compressor.
5. Check the engine cooling fan is drawing cool air
through the condenser.
6. Check the compressor drive belt tension.
7. Check the condenser core and grid is clean and
free of obstruction.
8. Check the cab air filter is clean and free of obstruction.
9. Check the evaporator fins are not plugged or excessively dirty.
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Attaching The Gauge Set To The Loader Backhoe

1.
2.
3.
4.
5.
Low side gauge

High side gauge
Shut-off Valve
Test Hose to High Side Service Connector
Centre Hose (Not Used)
6.
7.
8.
9.
Test Hose to Low Side Service Connector

Shut-off Valve
Low Pressure (Suction) Side Service Valve
High Pressure (Discharge) Side Service Valve
Performance Testing The Air Conditioning System

The manifold gauge set is the most important tool
used in testing and servicing the air conditioning
system.
Operating Precautions
NOTE: for Dealers who posses the latest design

level of refrigerant recovery, recycling and recharging station, these gauges are an integral part of the
machine.
In the closed position, refrigerant circulates around

the valve stems to the gauges. Therefore, when the
manifold gauge set is connected into a system,
pressure is registered on both gauges.
Z NEVER open the HIGH SIDE shut off valve when
the system is operating.
Z ALWAYS open the LOW SIDE shut off valve when
adding refrigerant.
The following instructions for performance testing

the air conditioning system is based on the use of
the gauge set shown. The principal of operation is
however similar when testing the system using a recovery and recharging station with integral gauges.
When using this type of equipment always consult
the manufacturers operating instructions.
IMPORTANT: always ensure the shut-off valves are

closed (turn clockwise until seated) during all test
operations.
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Attaching The Gauge Set To The Loader Backhoe
S WARNING
To avoid personal injury, stop the loader backhoe
engine during connection of the manifold gauge set.
1. Check that the gauge set shut off valves are
closed (turned fully clockwise).
2. Connect the high side gauge hose (normally
red) to the high pressure (discharge) side service valve and the low side gauge hose (normally
blue) to the low pressure (suction) side service
valve on the loader backhoe. Ensure the hose
connections are fully tightened.
IMPORTANT: prior to connection of the manifold
gauge set, identify the suction (low pressure) and
discharge (high pressure) service gauge ports. The
high pressure service valve is always in the line from
the compressor to the condenser.
The high and low pressure service valves on the
loader backhoe are spring loaded valve and will be
automatically opened when the test hose is connected.
NOTE: the test hose must incorporate a valve depressor to actuate this type of valve.
The service valves have a protective cap. This cap
must be removed for test gauge connections and replaced when service operations are completed.
Test Procedure
After the manifold gauge set has been connected
and before pressure tests can be made, the system
must be stabilized as follows:
1. Apply the parking brake, check the gearshift levers are in neutral and close the cab windows
and doors.
2. Re-check that both the high and low side shut
off valves on the manifold gauge set are fully
closed.
3. Run the engine at 1000-1200 rpm.
4. Turn the heater temperature control OFF.
5. Operate the system at maximum cooling, with
the blower fan at high speed for 10 minutes to
stabilize all components.
6. Check the manifold low pressure gauge reading
is within the specified range of approximately
0.28-2.48 bar.
7. Check the manifold high pressure gauge reading and compare the reading to the pressure indicated on the pressure temperature chart
below.
8. Measure and compare the temperature of conditioned air entering the cab through the louvered air vents with the ambient air at the air
intake filters on the outside of the cab.
If the system is operating correctly the conditioned air entering the cab should be 6-9 C
cooler than the ambient temperature of the outside air.
9. If it is confirmed that the system is not operating
correctly refer to the fault diagnostic charts and
performance test gauge reading examples on
the following pages for possible corrective action.
S WARNING
A significant amount of refrigerant vapour may have
condensed to a liquid at the service fitting at the high
side of the compressor. Use a cloth or other protective material when disconnecting the manifold hose
from this fitting to prevent personal injury to hands
and face.
APPROXIMATE HIGH PRESSURE GAUGE READINGS

Ambient air temperature
High pressure gauge reading
bar
27
10.0/11.6
29
11.2/12.7
32
12.3/13.8
35
13.3/15.2
38
14.5/16.7
41
16.0/18.3
43
17.3/20.0
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PERFORMANCE TEST DIAGNOSIS

Pressure gauge values: Low pressure - Low
High Pressure - Low
PROBLEM
Evaporator air not cold
POSSIBLE CAUSE
Low refrigerant charge
CORRECTION
Perform leak tests and repair.
Evacuate the system.
Charge system, re-test system.
Evaporator air warm
Extremely low refrigerant charge
Perform leak tests and repair.

Charge system, re-test system.
Evaporator air cool but not

Expansion valve not permitting suffisufficiently cold
cient flow
Low pressure switch cutting
Stuck valve
out
Expansion valve to evaporator
tube shows considerable condensation or frost
Too cold to touch
Check expansion valve as follows:

Set for maximum cooling.
Low pressure gauge should lower
slowly.
If expansion valve is defective:
Discharge the system.
Replace the expansion valve.
Charge the system.
Re-test.
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PERFORMANCE TEST DIAGNOSIS CHART

Pressure gauge values: Low pressure - High
High Pressure - High
PROBLEM
Evaporator air warm
Liquid line hot (condenser outlet to expansion valve tube)
POSSIBLE CAUSE
Improper operation of condenser
CORRECTION
Inspect for dirty condenser restricting
air flow and cooling.
Check operation of condenser cooling
fans. Repair or replace as needed.
Check for overcharge as follows:
High pressure switch cutting

out
Overcharged with refrigerant

Air in system
Expansion valve allowing too much

refrigerant to flow through the evaporator
Stop the engine. Recover and recycle

the charge using correct recovery
equipment.
Recharge the system with the correct
quantity of refrigerant, replacing any
lost lubricant. Recheck performance
of air conditioning system.
Check expansion valve as follows:
Set for maximum cooling.
Low pressure gauge should lower
slowly.
If expansion valve is defective:
Charge the system.
Re-test.

Pressure gauge values: Low pressure - Low
High Pressure - High
PROBLEM
Insufficient cooling
POSSIBLE CAUSE
Restriction in liquid line
CORRECTION
Replace receiver/drier.
Inspect all lines and tubing from compressor outlet to expansion valve.
Replace if needed.
Charge the system.
Re-test.
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High Pressure - Low
PROBLEM
POSSIBLE CAUSE
Internal leak in compressor (reed
valves, gasket, worn or scored piston rings or cylinder)
CORRECTION
Replace the compressor.
Charge the system.
Re-test.

Pressure gauge values: Low pressure - Normal
High Pressure - Normal
PROBLEM
Insufficient cooling
Low pressure reading does
not fluctuate with changes in
temperature control switch
(pressure should lower until
compressor cycles)
POSSIBLE CAUSE
System low on charge. Air or moisture present in system
CORRECTION
Perform leak test.
Repair leaks.
Replace receiver/drier.
Check oil level.
Charge the system.
Re-test.

High Pressure - Normal
PROBLEM
Compressor cycles ON and
OFF too frequently
POSSIBLE CAUSE
Defective temperature control (thermostatic) switch
CORRECTION
Stop engine and shut off A/C.
Replace temperature control switch.
Re-test system and check compressor cycling.
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EXAMPLES OF MANIFOLD GAUGE READINGS AND INTERPRETATIONS

The following examples show typical low and high pressure gauge readings obtained when performance testing the air conditioning system with an ambient temperature of 35 C.
The recommended corrective action is based on a similar fault as identified in the performance test diagnosis
charts.
PERFORMANCE TEST EXAMPLE 1
3
F28697
Performance Test Example 1

1. High side low
2. High side hand valve closed
3. High side hose connected to high side service
connector
4. Not used
5. Low side hose connected to low side service

connector
6. Low side hand valve closed
7. Low side low
PROBLEM
Little or no cooling.
3.
4.
5.
6.
CAUSE
Refrigerant slightly low.
CONDITIONS*
Low side pressure too low.
Gauge should read 1-2 bar.
High side pressure too low.
Gauge should read 13.3-14.8 bar.
Evaporator air not cold.
CORRECTIVE PROCEDURES
1. Leak test the system.
2. Repair leaks. (Discharge and recover the refrigerant from the system; replace lines or components).
Check compressor oil to ensure no loss.

Charge the system.
Performance test the system.
DIAGNOSIS
System refrigerant is low. May be caused by a small
leak.
NOTE: * test procedure based upon ambient temperature of 35 C.
For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature
chart.
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3
F28698

1. High side low
connector
4. Not used

connector
7. Low side normal
PROBLEM
Insufficient cooling.
DIAGNOSIS
System refrigerant is extremely low. A serious leak
is indicated.
CAUSE
Refrigerant excessively low.
CONDITIONS*
Low side pressure very low.
Gauge should read 1-2 bar.
High side pressure too low.
Evaporator air warm.
Low pressure switch cutting out.
1. Leak test the system.
2. Discharge and recover the refrigerant from the
system.
3. Repair leaks.
4. Check compressor oil to ensure no loss.
5. Evacuate the system.
6. Charge the system.
7. Performance test the system.

chart.
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3
F28699

1. High side normal
connector
4. Not used

connector
7. Low side low
PROBLEM

system.
3. Repair leaks.
4. Replace receiver/drier.
5. Check compressor oil to ensure no loss.
CAUSE
Air in the system.
CONDITIONS*
Low side pressure reading does not change when
compressor cycles ON and OFF.
High side pressure slightly high or slightly low.
1. Leak test the system. Give special attention to
the compressor seal area.
DIAGNOSIS
Air or moisture in system. System not fully charged.
chart.
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35
3
F28700

1. High side low
connector
4. Not used

connector
7. Low side high
PROBLEM
1. Replace the compressor.
CAUSE
Compressor malfunction.
DIAGNOSIS
Internal leak in compressor caused by worn or
scored pistons, rings, or cylinders.
CONDITIONS*
Low side pressure too high. Gauge should read 1-2
bar.
High side pressure too low. Gauge should read
13.3-14.8 bar.

chart.
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3
F28701

1. High side high
connector
4. Not used

connector
7. Low side high
PROBLEM
Little or no cooling. Engine overheats in some cases.
At this point, operate the system and check its performance. If still unsatisfactory, proceed as follows:
system.
5. Remove the condenser and clean and flush it to
ensure a free flow of refrigerant. Or, if the condenser appears to be unduly dirty or plugged,
replace it.
7. Evacuate the system, and recharge it with the
correct quantity of refrigerant.
CAUSE
Condenser not functioning properly.
CONDITIONS*
bar.
High side pressure too high. Gauge should read
13.3-14.8 bar.
Liquid line hot.
High pressure switch cutting out.
1. Check belt. Loose or worn drive belts could
cause excessive pressures in the compressor
head.
2. Look for clogged passages between the condenser fins and coil, or other obstructions that
could reduce condenser airflow.
3. If engine is overheating replace engine thermostat and radiator pressure cap.
DIAGNOSIS
Lack of cooling caused by pressure that is too high
on the high side, resulting from improper operation
of condenser. (Refrigerant charge may be normal or
excessive).
chart.
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3
F28701

1. High side normal
connector
4. Not used

connector
7. Low side normal
PROBLEM
system.
CAUSE
Large amount of air in system.
CONDITIONS*
bar.
13.3-14.8 bar.
DIAGNOSIS
Air in the system. Air and humidity contained in it
contaminate the system: therefore, it will operate incorrectly.
chart.
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3
F28704

1. High side high
connector
4. Not used

connector
7. Low side hide
PROBLEM
2. If the test indicates that the expansion valve is

defective, proceed as follows:
Discharge and recover the refrigerant from the
system.
Charge the system.
CAUSE
Improper operation of thermostatic expansion valve
(stuck open).
CONDITIONS*
bar.
High side pressure too high. Gauge should read
13.3-14.8 bar.
Evaporator and suction hose (to compressor) surfaces show considerable moisture.
1. Check for sticking expansion valve as follows:
Operate the system at maximum cooling.
Check the low side gauge. The pressure should
lower slowly.
DIAGNOSIS
Thermostatic expansion valve is allowing too much
refrigerant to flow through the evaporator coils.
Valve may be stuck open.
chart.
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3
F28705

1. High side low
connector
4. Not used

connector
7. Low side low
PROBLEM

lower slowly.
2. If the procedure outlined in Step 1 shows that
the expansion valve is defective, proceed as follows:
Charge the system.
CAUSE
Improper operation of thermostatic expansion valve
(stuck open).
CONDITIONS*
Low side pressure too low (zero or vacuum). Gauge
should read 1-2 bar.
High side pressure low. Gauge should read 13.314.8 bar.
Evaporator air cool, but not sufficiently cold.
Evaporator inlet pipe surface shows considerable
moisture or frost.
Low pressure switch cutting out.
1. Place finger on expansion valve to evaporator
tube. If too cold to touch, proceed as follows:
DIAGNOSIS
Expansion valve is not permitting a sufficient flow of
refrigerant. May be caused by valve stuck in restricted or closed position.
chart.
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3
F28706

1. High side low
connector
4. Not used

connector
7. Low side low
PROBLEM
1. Check for sticking expansion valve as follows:
lower slowly.
2. If the test indicates that the expansion valve is
defective, proceed as follows:
Discharge and recover the refrigerant from the
system.
Charge the system.
CAUSE
Restriction in high side of system.
CONDITIONS*
Low side pressure too low. Gauge should read 1-2
bar.
13.3-14.8 bar.
NOTE: a normal or high reading of the high side
pressure gauge under these conditions indicates
the system is overcharged or the condenser or receiver/dryer is too small.
Evaporator only slightly cool.
Liquid line and receiver/dryer are cool to touch and
show frost or considerable moisture.
DIAGNOSIS
Thermostatic expansion valve is allowing too much
refrigerant to flow through the evaporator coils.
Valve may be stuck open.
chart.
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3
F28707

1. High side normal
connector
4. Not used

connector
7. Low side gauge
Compressor cycles on at 2.3 bar
Compressor cycles off at 1.9 bar
PROBLEM
Compressor cycles (cuts in and out) too rapidly.
3. Make sure the switchs temperature sensor is installed in the same position and depth (in evaporator core) as previous.
CAUSE
Thermostatic switch defective.
CONDITIONS*
Low side pressure readings too high during both ON
and OFF compressor cycles and between cycles.
Readings should be:
0.8-1.0 bar - cycle (OFF)
2.5-2.7 bar - cycle (ON)
1.7-1.9 bar - between cycles.
High side pressure normal. Gauge should read
13.3-14.8 bar.
1. Stop engine and shut off A/C.
2. Replace thermostatic switch with switch of same
type.
DIAGNOSIS
Defective thermostatic switch.
chart.
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LEAK TESTING, DISCHARGING AND CHARGING THE AIR CONDITIONING SYSTEM

Leak Testing
To perform a leak test if refrigerant leakage is suspected, use a leak detector following the manufacturers instructions.
Leak detectors use light or sound dependent upon
the type used to alert the operator of a leak. If the
leak detectors sensitivity is adjustable, be sure you
calibrate the detector according to the manufacturers instructions before use.
When using a leak detector, keep in mind that a very
slight amount of leakage in the compressor pulley
area is normal and does not necessarily indicate a
repair is required.
When a leak is located, follow these steps.
Z Discharge the system using a certified refrigerant
recovery system.
Z Repair the leak.
Z Evacuate the system.
Z Partially charge the system with 400 g of refrigerant.
Z Check system for leaks.
Z Fully charge the system.
Always check the system for leaks as a final test after evacuating and before recharging. Refer to
Evacuating the system.
F28708
Discharging the system

Legislation has been introduced banning the release
of refrigerant into the atmosphere.
Whenever overhauling the air conditioning system
or performing other tasks which require the air conditioning system to be dismantled it is necessary to
discharge the refrigerant gas before commencing
repair.
Before you can dismantle an air conditioning system
for repairs, you must discharge and recover the refrigerant using a certified recovery unit in accordance with the manufacturers instructions.
Shown is a combined refrigerant recovery, evacuation and recycling/charging station. This equipment
removes HFC 134a refrigerant from the air conditioning system, recycles and recharges all in one
hook up.
The unit is designed to be used with the manifold
gauge set built into the control panel.
F28709
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Connecting recovery evacuation and recycling/charging station to the loader backhoe

1. Built in manifold gauge set
2. Recovery/recharging unit
Other recovery systems are available where the
manifold gauges are not an integral part of the machine. When this type of equipment is used a separate manifold gauge set must be used.
The following is a summary of the steps for discharging the system using a recovery/recycling unit.
S WARNING
Never discharge refrigerant gas into the atmosphere. Always wear safety goggles and gloves
when working with refrigerant. Only use authorized
refrigerant tanks.
IMPORTANT: always follow the manufactures instructions when operating recovery equipment.
1. Run the vehicles air conditioning system for a
few minutes.
2. Set up the recovery unit following manufacturers instructions. Ensure that the units red (high
side) hose is connected to the high side (discharge) fitting and the blue (low side) hose to
the low side (suction) fitting.
3. Low side (suction) service valve (blue hose)

4. High side (discharge) service valve (red hose)
NOTE: if a unit requiring the manifold gauge set is
being used, the low and high sides of the manifold
set are connected to the low and high sides of the
loader backhoe air conditioning system. The hose
from the recovery unit is then connected to the manifold centre port.
3. To recover refrigerant, open both high and low
side valves on the control panel or the valves on
the manifold gauge set if being used.
4. Open the valves labelled gas and liquid on
the recovery unit refrigerant tank.
5. Plug in the units power cord.
6. Operate the recovery system in accordance with
the manufacturers instructions.
The compressor will shut off automatically when the
recovery is complete.
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3.5
Copyright
FLUSHING THE SYSTEM
3
F28711
Manifold side gauge

1.
2.
3.
4.
High side gauge

High side shut-off valve
High side hose
Centre service hose
Air conditioning systems may occasionally become

contaminated with solid particles. This contamination may be the result of allowing dirt to enter the
system while it was open, from aluminium corrosion
or sludge, or from disintegrated compressor reed
plates. Contamination of this nature can result in
plugged evaporators, condensers and expansion
valves.
Flush System with dry nitrogen.
Each individual component must be flushed after
disconnecting every hose fitting.
The compressor and expansion valve can not be
flushed, therefore, the compressor should be disassembled and cleaned or replaced and the expansion valve should be replaced. When flushing the
system always replace the receiver/drier.
5. Low side hose

6. Low side shut-off valve
7. Low side gauge
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45
NOTE: never use any solvent for flushing an air conditioning system other than a special flush solvent
made specifically for air conditioning systems. Always follow the manufacturers recommendations
and directions for using the flushing equipment and
solvent.
Re-assemble and evacuate the system to remove
air and moisture as described in Evacuating the
System.
F28712
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3.6
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EVACUATING THE SYSTEM
IMPORTANT: a system in which the refrigerant has

been recovered to facilitate repairs, must be evacuated before new refrigerant is installed.
Air and moisture are removed by evacuating the
system using a vacuum pump.
The automatic recycling, recharge and evacuation
stations or evacuating and charging stations available throughout the air conditioning industry incorporate a vacuum pump within the assembly. If this type
of equipment is not available a separate vacuum
pump and manifold gauge set must be used.
As the system is evacuated the boiling point of any
moisture within the system is similarly lowered. As
the vacuum increases, the boiling point decreases
to below that of the ambient temperature and, consequently, the moisture is boiled away.
The relationship of system vacuum to the boiling
temperature at which the water vapour is removed
from the system is as follows:
System
Vacuum
System
Vacuum
Temperature
In
Mercury
In Cm. of
Mercury
28.0
71.0
38
28.9
73.4
27
29.4
74.6
16
29.7
75.4
29.8
75.7
-7
29.9
75.9
-18
NOTE: for every 305 m above sea level, the vacuum

gauge reading must be corrected by adding 2.54 cm
of mercury to compensate for the change in atmospheric pressure.
IMPORTANT: be sure the system is completely discharged as refrigerant will damage the vacuum
pump.
1. If the manifold gauge set is being used connect
the low and high sides of the manifold to the low
and high sides of the vehicle air conditioning
system as described for discharging the system.
Connect the manifold centre hose to the vacuum pump suction port as per the manufacturers
instructions.
Fully open both the low and high side gauge
shut off valves.
2. If a combined recovery/evacuation unit is to be

used attach the unit to the air conditioning system in accordance with the manufacturers instructions. Be sure to read all installation and
operating instructions carefully before starting
the unit.
3. After starting the evacuation cycle, note the low
side gauge to be sure the system pulls down
into a vacuum.
4. Time the evacuation for a minimum of 30 minutes from the point when lowest vacuum is attained.
5. Thirty minutes later when the low side gauge attains the lowest steady vacuum, stop the evacuation process.
NOTE: the vacuum pump achieves ultimate vacuum with the vented exhaust valve closed. Do not
evacuate too quickly as oil may be drawn from the
system.
6. Check the system by closing the gauge shut-off
valves, turning the vacuum pump off and noting
the low side gauge reading. A loss of more than
5 cm of vacuum in 5 minutes indicates either a
leak or moisture in the system.
7. If the gauge needle remains stationary and the
vacuum is maintained for 3-5 minutes, close
both the high and low side manifold hand
valves, turn off and disconnect the centre hose
from the pump. The system is now ready for
charging.
8. If a leak is detected, charge the system with approximately 400 g of refrigerant, see charging
the system and locate the leak using a leak detector.
9. Once the leak is located discharge and recover
the refrigerant in the system, repair the leak,
then repeat the evacuation procedure.
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3.7
CHARGING THE SYSTEM
IMPORTANT: be sure there are no leaks in the system and the system has been fully evacuated. Observe all safety recommendations when handling
refrigerant HFC 134a, see Precautions when Handling Refrigerant HFC 134a in this Section.
1. Ensure the charging unit is correctly connected
to the loader backhoe air conditioning system in
accordance with the manufacturers instructions.
2. If a charging unit, in conjunction with the manifold gauge set is used, open the high and low
side hand valves on the manifold.
3. Charge the system with 0.75 kg of refrigerant as
per the manufacturers instructions.
4. If the charging rate becomes very slow close
the high side valve carefully, start the loader
backhoe and set engine speed to idle. Turn ON
the air conditioning so that the compressor can
47
pull the remainder of the refrigerant into the system.

5. If the refrigerant charge will not completely
transfer to the air conditioning system, recover
and recharge the system.
6. Close the high and low side valves on the units
control panel, or manifold gauge set if being
used and test the air conditioning as detailed in
Performance testing the air conditioning system
on page 26.
NOTE: after charging a system use the following
start up procedure to ensure the lubricating oil is
properly dispersed around the system.
Z Ensure air conditioning is switched OFF.
Z Start the engine and bring speed down to idle.
Z Turn the air conditioning ON and allow system to
operate for at least one minute before increasing
engine speed.
Connecting recovery evacuation and recycling/charging station to the loader backhoe

1. Built in manifold gauge set
2. Recovery/recharging unit
3. Low side (suction) service valve (blue hose)

4. High side (discharge) service valve (red hose)
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3.8
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COMPONENTS OVERHAUL
GENERAL
S WARNING
Before disconnecting components in the air conditioning system the refrigerant gas must be discharged and recovered using a certified recovery
system. Refer to Discharging the system. Do Not
discharge the gas into the atmosphere.
If an air conditioning component is to be replaced
during a system overhaul it is necessary to drain any
refrigerant oil that has collected in the component
being replaced into a clean calibrated container.
A volume of clean refrigerant oil equivalent to that removed from the replaced component must then be
added to the new item before being installed onto the
loader backhoe.
Upon completion of the repair evacuate, recharge,
leak test and performance test the system to ensure
correct operation.
EXPANSION VALVE
The expansion valve is not a serviceable item and
must be replaced if defective.
1. Fully discharge the air conditioning system.
2. Remove the seat to gain access to the valve.
3. To gain access to the expansion valve partially
lift the evaporator core from its position in the
cab floor.
4. Remove the screw securing the inlet and outlet
connections to the valve and pull valve from tubing.
5. Replace the O-ring seals and lubricate with refrigerant oil prior to installing the valve using disassembly procedure in reverse.
6. Evacuate, leak test and recharge the system.
F28714
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EVAPORATOR
1. Discharge and reclaim refrigerant gas using certified recovery systems.
2. Remove the seat and cover plate to reveal evaporator assembly (1).
3. Remove temperature cycling control thermocouple.
4. Disconnect tubing to expansion valve.
5. Remove evaporator.
6. Check the evaporator assembly fins for damage.
Straighten fins if necessary.
7. Clean the evaporator core of all foreign material
to be sure it is free of obstructions.
8. Check the evaporator assembly for indications
of refrigerant leakage. If damage or leaks are evident, replace the evaporator core.
If a new evaporator is to be installed drain the refrigerant oil in the evaporator into a clean calibrated
container. Measure the quantity of oil obtained and
add the same quantity of new refrigerant oil directly
into the replacement evaporator core.
Install evaporator using disassembly procedure in
reverse.
Evacuate, leak test and recharge the system.
AIR CONDITIONER TEMPERATURE CYCLING
CONTROL
1. Remove the seat mounting plate.
2. The temperature cycling switch (2) is mounted to
the side of the blower motor assembly.
3. Carefully pull and disconnect the switch wiring at
the connector.
4. Remove temperature control switch and replace
as required.
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LOW PRESSURE CUT-OUT SWITCH

1. With the engine OFF check continuity across the
switch contacts. If the switch (1) indicates an
open circuit, replace it as described below.
IMPORTANT: the pressure switch can not be replaced without discharging the system.
2. Remove switch by unscrewing from self sealing
Schrader valve.
3. Replace with new switch and connect to harness.
BLOWER MOTOR ASSEMBLY
If necessary, the blower motor can be removed without discharging the system as follows:
1. Remove the cab seat mounting plate.
NOTE: take care not to damage hoses during this
operation. If the cab heater hoses restrict movement
of the housing drain the heater assembly and disconnect the hoses.
2. Disconnect the motor wiring connector block.
3. Remove the remaining motor securing screws
and withdraw motor.
4. Re-assembly follows the disassembly procedure
in reverse.
RECEIVER DRYER
The receiver/dryer (3) cannot be overhauled and
must be replaced as an assembly. The receiver/dryer assembly should be replaced if it is suspected that
moisture is in the system.
The receiver dryer must also be replaced if the system has been discharged and the air conditioning
joints disconnected.
1. Discharge and reclaim refrigerant gas using certified recovery systems.
2. Disconnect the hoses and switch and remove
the dryer from the loader backhoe.
3. Drain the refrigerant oil from the receiver dryer
into a clean calibrated container. Measure the
quantity of oil obtained and add the same quantity of new refrigerant oil directly into the new
item.
4. Cap and plug all fittings to prevent any dirt entering the system.
5. Install a new receiver dryer.
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CONDENSER
1. Unscrew and remove the fastening screws (2).
Remove the front grill (1).
2. Unscrew and remove the nut (3). Remove the

horn (4). Unscrew and remove the nut (5). Remove the fuel cooler (6).
3. Unscrew and remove the fixing upper nut (7) and

loosen the fixing lower nut. Move the dryer filter
(8) to the right side.
4. Unscrew and remove the nuts (9).
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5. Move the condenser (10) forward.

Clean the condenser (10) by compressor air.
CAB AIR FILTER

1. Before servicing the filter (1), switch off the blower and close all windows and one door. Slam the
final door closed and the resulting back pressure
will dislodge most of the loose dirt from the underside of the filter.
2. Remove the filter and clean it by blowing with
compressed air not exceeding 2 bar.
IMPORTANT: make sure you protect your face before using compressed air.
Blow the dust from the upper surface through the
element to the underside. Hold the nozzle at
least 300 mm from the element to prevent damage to the paper pleats.
3. Clean both filter chambers with a damp, lint free
cloth.
4. Replace the filter element with the rubber seal
uppermost and re-install the covers.
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3.9
53
COMPRESSOR
SPECIFICATIONS
Basic compressor specifications
Displacement ............................................................................................................................................155 cc
Weight........................................................................................................................................................9.9 kg
Oil type........................................................................................................................................................SP20
Rotation.............................................................................................................................. CW (Clockwise only)
Air gap, clutch, compressor and pulley ............................................................................................. 0.9-0.8 mm
Belt tension
Measure at the widest gap.................... 10 mm deflection with 1 kg force applied midway between the pulleys
Speed rating
MAXIMUM RPM
Constant
Downshift
6000
8000
Tightening torques
COMPONENT
Nm
Armature retaining nut, M8
17.72.9
Cylinder head bolts, M6
13.72.9
Cylinder head bolts, M8
34.34.9
Clutch dust cover screw, M5

Oil filler plug
92
19.64.9
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FAULT FINDING
During diagnosis follow the inspections procedures in the sequence shown until a default is found. Then perform the repair in the Cause and Remedy section. If this repair does not fully solve the problem, proceed to
the next inspection step.
PROBLEM
Unusually high suction pressure with unusually low discharge pressure
CAUSE
Valve plate test
Unusually low suction and dis- Check for low refrigerant charge
charge pressure
Leak check compressor
Intermittent or inoperative
Rough running
Replace or repair:
Broken head or block gasket.
Broken or deformed reed valve.
Foreign substance under reed valve
or gasket.
Replace or repair:
Shaft seal leak.
Leak check and diagnose system
Cylinder head leak.

Gasket leak.
Oil filler plug leak.
Cracked cylinder block.
Front housing O-ring leak.
Check belt tension
Replace.
Check clutch air gap
Adjust air gap.
Check clutch volts, amps, coil lead

wire
Replace or repair:
Broken lead wire.
Clutch coil defect - Internal.
System ground (see system manual).
Shaft turning smoothness test
Compressor failure - Internal.
PROBLEM
Clutch engaged
CORRECTION
CAUSE
CORRECTION
Check compressor mounting compo- Replace or repair.

nents
Check engine components
Replace or repair.
Check for intermittent or slipping

clutch
Adjust air gap - defective coil.
Check for proper refrigerant charge
Recharge and recheck.
Check clutch bearing
Replace rotor / Armature assembly.
Oil level procedure
Shaft turning smoothness test
Compressor failure (Internal).
Remove valve plate and inspect
Replace or repair:
Broken discharge valve reed or
retainer.
Broken suction valve reed.
Broken gasket.
Clutch disengaged chattering Check air gap
Replace or repair:
Adjust air gap.
Defective clutch pulley or front plate.
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55
13
10
7
12
1
11
2
5
8
14
4
1
9
F28721
Removal
Discharge the air conditioning system. Disconnect
the electrical harness of the compressor (12) from
the electrical harness of the engine. Disconnect tubing to compressor. Remove the washer (7) and the
screw (1). Remove the protective guard (13). Remove the bolt (11). Remove the nut (14) and the
screw (9).
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Remove the washers (5), the nut (6), the screw (2)
and the block (8). Remove the screw (1), the washers (3) and the belt tensioner (4). Remove the screw
(10), the washers (2) and the compressor (12).
Installation
Installation is the reversal of the removal but the following points should be noted.
Z Torque the fixing bolts to 40-51 Nm.
NOTE: it is recommended that a new receiver/drier
assembly is installed after any system component
replacement or any repair that requires entry into
the system.
Z Drain the oil from the new compressor to be fitted
into a clean container, or if the old compressor is to
be refitted, obtain a new can of refrigerant oil.
Z Calculate the amount of oil to be installed and refill
the compressor.
Z Reconnect the hoses to the compressor and tighten all bolts and hoses.
F28723
After charging a system use the following start up

procedure to ensure the lubricating oil is properly
dispersed around the system:
Z Ensure air conditioning is switched OFF.
Z Start the engine and bring speed down to idle.
Z Turn the air conditioning ON and allow system to
operate for at least five minutes before increasing
engine speed.
A correctly tensioned belt can be deflected 13-19
mm when hand pressure is applied midway between the alternator and crankshaft pulley.
Once adjusted re-torque the tension arm bolt to 33.9
Nm.
F28725
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The compressor drive belt (1) can be tensioned by

rotation of the idler arm (2). Slacken the idler arm
bolt and adjust the arm to a belt deflection of 16 mm.
Once adjusted re-torque the tension arm bolt to 33.9
Nm.
F28726
OVERHAUL COMPRESSOR
Before any internal repair is done, drain the oil from
the compressor:
Z Remove the oil plug and drain as much oil as possible into a suitable container.
Z Remove the caps (if present) from suction and discharge ports.
Z Drain oil from the section and discharge ports into
suitable container while turning the shaft clockwise
only with a socket wrench on the armature retaining nut.
CC
F28727
Z Measure and record the amount of oil discharged.

Z Inspect the oil for signs of contamination such as
discoloration of foreign material.
F28728
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CLUTCH
10
F28729
1.
2.
3.
4.
5.
Cover screw
Dust cover
Nut
Plate
Shims
Disassembly
All clutch servicing should be done with the compressor removed from the vehicle. Support the compressor. If using a vice, do not hold on to the
housing. If dust cover (2) is present, remove the 3 or
6 bolts (1) holding it in place and remove cover. If
auxiliary sheet metal pulley is present, remove the
screws holding it in place. Then remove pulley.
Attach tool to the cover on the front of the clutch
plate and placing a socket and ratchet through the
tool remove the cover attaching nut (3).
6.
7.
8.
9.
10.
Cover
Snap ring
Rotor assembly
Snap ring
Field coil
F28730
Using the front plate tool and a tommy bar hold the
clutch plate stationary.
Place the bolt into the tool and by tightening the bolt
onto the end of the shaft the front plate will be extracted from the shaft.
If shims (5) are above shaft key, remove them now.
If shims (5) are below shaft key, the key and bearing
dust cover (if present) must be removed before
shims can be removed.
Remove dust cover (6) (if present). Use caution to
prevent distorting cover when removing it.
Remove shaft key by tapping loose with a flat blade
screwdriver and hammer. Remove shims (5). Use a
pointed tool and a small screwdriver to prevent the
shims from binding on the shaft.
F28731
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Remove the snap ring (7), remove the shaft key and
lift the pulley assembly from the compressor.
F28732
Inspect the rotor assembly (8) for wear and replace

the assembly as necessary.
F28733
Remove the field coil wire retaining clip.
F28734
Remove the snap ring (9) of the coil.
F28735
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Lift the coil (10) from the housing and replace as required.
10
F28736
Assembly
Install the coil (10), making sure that the wire is located behind the clip on the outside of the body and
that the snap ring (9) is located in the groove.
10
F28737
Position the rotor (8) on the housing hub and carefully slide the rotor (8) down the shaft.
F28738
Install the snap ring (7).
F28732
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Replace the plate (4) and retaining nut and tighten

to a torque of 18 Nm.
F28730
Check the clearance between the plate (4) and rotor

(8). This should be consistent around the circumference and be between 0.4-0.8 mm.
NOTE: if the air gap is not consistent, lightly pry up

on the counter weighted front plate at the low spots
or lightly tap down at the high spots.
8
F28741
If the clearance is not within specification the shims

(5) under the front plate should be added to or subtracted from, until the correct clearance is obtained.
NOTE: new shims are available in sizes 1.00, 0.50

and 0.13 mm.
Replace dust cover (2) if present and torque 3 on 6
bolts (1).
F28742
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COMPRESSOR
10
F28743
Air conditioning refrigerant compressor

1.
2.
3.
4.
5.
Shaft key
Ring
Circlip
Gasket
Plug
Removal
The refrigerant must be discharged from the system
and the compressor removed from the vehicle prior
to replacing the shaft seal.
Z Remove the armature plate, as detailed in the
steps of clutch disassembly.
Z Remove the shaft key (1), shims and ring (2) to expose the snap ring (3).
Z Remove the snap ring (3).
6.
7.
8.
9.
10.
Gasket
Plate
Head gasket
Cylinder head
Screw
F28744
Insert the seal remover/installer tool (A).

Twist the tool to engage the slots in the seal. Pull up
to remove and discard the seal (4).
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63
Installation
Thoroughly clean the seal cavity in the hub. Use lint
free cloth only.
Ensure the new hub O-ring is installed onto the seal
assembly. Dip the new seal assembly in clean refrigerant oil and attach to the seal remover/installer
tool.
F28746
Completely insert the new seal (4).

NOTE: if remover/installer tool (A) is not available,
position the seal squarely in the hub and tap gently
until fully seated.
Install the snap ring (3). If the snap ring has a bevelled edge this should face outwards.
F28744
Install a new ring (2) and push into position.
F28713
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Position the shims over the shaft and refit the shaft
key.
Reinstall the plate as described in clutch reassembly.
F28911
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CYLINDER HEAD
Disassembly
Drain the refrigerant oil from the compressor into a
clean calibrated container. Measure and record the
quantity of oil obtained. This information is required
during installation of the new or overhauled unit.
Remove the six cylinder head bolts (10) and using a
hide mallet, gently tap the cylinder head (9) free.
The use of a gasket scraper may also be required to
free the cylinder head from the compressor body.
10
F28747
If the plate (7) and/or cylinder head are to be reused,

carefully remove the gasket (8) using a suitable
scraper.
F28748
Gently pry the plate (7) free from the cylinder block
and remove the gasket (6).
Inspect the plate (7) for damage.
7
6
F28749
Reassembly
Coat the top of the valve plate with clean refrigerant
oil and reassemble the cylinder head using the reverse of the disassembly procedure.
When installing the gaskets and valve plate ensure
they are correctly positioned over the locating pins in
the cylinder block.
Install the cylinder head bolts and tighten using the
sequence shown. Torque initially to 20 Nm.
When the overhaul is complete add to the compressor a volume of oil equivalent to that drained prior to
disassembly, or as the reclaim measured fill.
F28750
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OIL RETAINED IN SYSTEM COMPONENTS

After replacement of individual system components it
will be necessary to add some oil to the system to
make up the amount lost in the removed component.
The table below shows some typical volumes for the
components. It is, however, still recommended that
the oil level measurement, described previously is
carried out after a new component has been installed
to establish correct oil quantity.
Component
Typical oil amount

fl.oz.
cc
Accumulator
2.0
60
Evaporator
2.0
60
Condenser
1.0
30
Receiver dryer
0.5
15
Hoses
0.3
10
Preliminary Inspection
1. Rotate the compressor shaft. Use a suitable
socket on the hub centre bolt or by hand using
the rubber dampers.
If severe roughness is felt while rotating the hub,
the compressor should be disassembled.
2. Using a 12 V battery, test the current absorption
of the field coil: it must be between 3.6 and 4.2 A.
Very high current readings indicate a short circuit in the field coil and no current reading indicate an open circuit. Replace coil with either
fault. Resistance of the coil using an ohmmeter
should be approximately 3.0 at 20 C.
A poor ground connection of the field coil will result in a low voltage.
3. Ensure clutch is disengaged and rotate pulley by
hand. If roughness in the bearing is felt, it will be
necessary to replace the pulley and bearing as
an assembly.
F28751
F28752
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3.10 SPECIAL TOOLS

Only certified refrigerant recovery, recycling and recharge equipment suitable for the type of refrigerant gas
HFC 134a should be used on these vehicles when servicing the air conditioning system.
This special equipment is available through recognized suppliers of air conditioning equipment.
P/N
DESCRIPTION
USE
380000315
Recovery / recharge portable system
Discharging and recovering of the

refrigerant
380000312
Evaporator and condenser cleaner
Evaporator and condenser cleaning
380000314
Electronic gas leak detector
Leak testing
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NOTES:
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580SR
580SR+
590SR
695SR

1. GENERALITIES............................................................................................................................................ 3
1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING.................................................................................................................................... 4
2. ELECTRICAL DIAGRAMS............................................................................................................................ 5
2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (580SR).......................................................... 5
2.2 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR)........................................................... 20
2.4 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR+/590SR) ............................................ 54
2.6 ELECTRICAL DIAGRAMS - 4WS POWERSHIFT CAB (695SR)........................................................ 84
3. CONTROLS AND INSTRUMENTS .......................................................................................................... 100
3.1 FRONT CONTROL PANELS (580SR / 590SR) ................................................................................ 100
3.2 FRONT CONTROL PANELS (695SR) .............................................................................................. 102
3.3 SIDE INSTRUMENT CLUSTER PANEL (580SR) ............................................................................. 104
3.4 SIDE INSTRUMENT CLUSTER PANEL (580SR+ / 590SR / 695SR)............................................... 106
3.5 SIDE INSTRUMENT CLUSTER (580SR).......................................................................................... 108
3.6 SIDE INSTRUMENT CLUSTER (580SR+ / 590SR / 695SR)............................................................ 110
3.7 IMMOBILISER CIRCUIT.................................................................................................................... 112
4. DIAGNOSTIC DISPLAY (580SR+ / 590SR / 695SR) ............................................................................... 113
4.1 SYMBOLS.......................................................................................................................................... 114
4.2 SETUP MENU ................................................................................................................................... 115
4.3 PROCEDURE ABOUT SELF TEST .................................................................................................. 116
4.4 ON BOARD ERROR CODE RETRIEVAL ......................................................................................... 117
4.5 BACKLIGHTING AND DIMMING....................................................................................................... 118
4.6 WORK HOURS.................................................................................................................................. 119
4.7 FUNCTIONAL DESCRIPTION .......................................................................................................... 120
4.8 WARNING SYSTEM.......................................................................................................................... 124
4.9 MAINTENANCE................................................................................................................................. 126
4.10 WARNING MESSAGES .................................................................................................................. 127
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5. STARTING SYSTEM ................................................................................................................................ 134

5.2 FAULT FINDING ................................................................................................................................ 135
5.3 STARTER MOTOR ............................................................................................................................ 138
6. ALTERNATOR .......................................................................................................................................... 144
6.1 SPECIFICATIONS ............................................................................................................................. 144
6.3 COMPONENTS ................................................................................................................................. 146
6.4 REMOVAL.......................................................................................................................................... 147
6.5 PRELIMINARY CHECK AND TESTS ................................................................................................ 148
6.6 FAULT FINDING ................................................................................................................................ 157
7. BATTERY.................................................................................................................................................. 158
7.1 SPECIFICATIONS ............................................................................................................................. 158
7.3 BATTERY REPLACEMENT............................................................................................................... 159
7.4 MAINTENANCE ................................................................................................................................. 161
7.5 TESTS................................................................................................................................................ 163
7.6 CONNECTING A BOOSTER BATTERY ........................................................................................... 165
7.7 BATTERY MASTER SWITCH ........................................................................................................... 165
8. COMPONENT TESTING .......................................................................................................................... 166
8.1 GENERAL INTRODUCTION ............................................................................................................. 166
8.2 COMPONENT TESTING ................................................................................................................... 167
8.3 GROUND POINTS............................................................................................................................. 167
8.4 ALTERNATOR ................................................................................................................................... 170
8.5 TRANSMISSIONS ............................................................................................................................. 170
8.6 PARKING BRAKE SWITCH............................................................................................................... 174
8.7 CAB.................................................................................................................................................... 175
8.8 4WD SWITCH .................................................................................................................................... 180
8.9 BRAKE PEDAL SWITCHES .............................................................................................................. 180
8.10 BRAKE OIL LEVEL WARNING LAMP............................................................................................. 181
8.11 FRONT WORK LAMP SWITCH (1) - REAR WORK LAMP SWITCH (2) MAIN LIGHT SWITCH.... 181
8.12 HAZARD SWITCH ........................................................................................................................... 182
8.13 HAZARD WARNING LIGHT RELAY................................................................................................ 182
8.14 MULTI FUNCTION SWITCH............................................................................................................ 183
8.15 FRONT WINDSHIELD WIPER MOTOR (1) - REAR WINDSHIELD WIPER MOTOR (2) ............... 183
8.16 4WS - STEERING SELECTOR SWITCH ........................................................................................ 184
8.17 STEERING CONTROL UNIT........................................................................................................... 185
8.18 4WS REAR AXLE STEERING SENSOR......................................................................................... 187
8.19 4WS FRONT AXLE STEERING SENSOR ...................................................................................... 187
8.20 STEERING SOLENOID VALVE....................................................................................................... 188
8.21 DIFFERENTIAL LOCK SWITCH (1) ................................................................................................ 189
8.22 LOADER .......................................................................................................................................... 190
8.23 BACKHOE........................................................................................................................................ 193
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1.
GENERALITIES
1.1
TEMPORARY WIRING HARNESS REPAIR
The following method to repair wiring is a temporary

expedient only. Wiring should be replaced as soon
as possible. Replacement of temporary repaired cables with new is particularly important if the loader
backhoe is to be used for spraying as chemicals can
enter the repaired area, travel up the cable and damage electrical components. Do not attempt to repair
the wire on any system sensors as these are sealed
and should only be replaced with a new component.
NOTE: when conducting a cable repair it is important that only RESIN CORED SOLDER is used. Use
of other types of solder ma result in further cable
damage.
To carry out a temporary repair, proceed as follows:
Z Locate damaged portion of cable then cut away
outer protective cover on both sides of the damaged area.
Z Peel back the cable from both ends of the damaged area and carefully cut away the inner cable
cover at the damaged area and strip about 13 mm
of insulation from the wires. Do not cut away any
wire strands.
Z Using a suitable solvent, clean about 50 mm from
each cover end. Clean the grey cable cover and
the individual leads.
Z Twist two bare leads together for each damaged
lead, being careful to match wire colours, then solder the leads using resin cored solder. Tape each
repaired lead with vinyl insulation tape.
Z Wind a layer of vinyl insulation tape up to the grey
cable cover at each end of the repair section. Make
a paper trough, then apply silicon rubber compound (non hardening sealant) over the repaired
section up to the cover ends. Sufficient sealant
must be used to fill the ends of the cut away area.
Z Allow the compound to cure then cover the area

with insulating tape taking the tape well over each
end of the repair. An overlap of at least 50 mm of
tape at each end is necessary.
Z Check to ensure the repair is satisfactory and secure the repaired cable so that repeat damage is
avoided.
NOTE: this is a temporary repair only. Ensure the
damaged cable is replaced as soon as possible to
prevent ingress of water or chemicals.
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4
1.2
Copyright
FAULT FINDING
PROBLEM
Electrical system is inoperative
CAUSE
Loose or corroded battery
connections
Clean and tighten connections
Sulphated batteries
CORRECTION
Check that the battery voltage with
open circuit is at least 12.6 V.
Check the electrolyte level and
density.
Restore the battery isolator switch.
Battery Isolator switch turned OFF
Starter motor speed too low, the

engine cranks slowly
Main machine fuse link blown

Loose or corroded connections
Low battery output voltage
Starter motor inoperative
Find the reason of the failure and

replace the connection fuse.
Clean and tighten loose connections.
density.
Use an oil with correct viscosity for

Incorrect viscosity of the engine oil the temperature conditions.
Transmission shift lever in gear
Move gearshift lever to neutral.
Loose or corroded connections
Clean and tighten loose connections.

Charge or replace the batteries.
Charge indicator lamp stays on

with engine running
Dead batteries
Low engine idle speed
Increase idle speed.
Loose belt
Check belt tension.
Malfunctioning battery
density.
Malfunctioning alternator
Batteries will not charge
Loose or corroded terminal

connections
Sulphated batteries
Charge indicator flashing

indicating excessive charging
voltage
Loose or worn belt

Malfunctioning alternator
Check alternator.
Clean and tighten the connections.
density.
Check the automatic belt tensioner.
Replace belt if required.
Check alternator.
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2.
ELECTRICAL DIAGRAMS
2.1
ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (580SR)
FUSE AND RELAY DESCRIPTION

Fuse
No.
Rating
K1
Forward-reverse travel gearshift lever relay
K2
Parking brake relay
Function
K3
Starting relay
Bucket level solenoid valve relay
F1A
7.5 A
Stopping the engine
K4
F1B
7.5 A
(+15) anti-theft device, grid heater
K5
Low and main beam relay

Inner front work light relay
F1C
10 A
Stop light switch
K6
Inner rear work light relay
15 A
Instrument power supply, switch

lamps, brake oil level sensor,
pneumo-electric seat, buzzer
K7
F2A
K8
Outer front work light relay
K9
Outer rear work light relay
K10
Reverse travel relay
F2B
F2C
15 A
Pilot control
F3A
3A
Rear right/front left side light,

instrument backlighting
F3B
3A
Rear left/front right side lights,

number plate light
F3C
10 A
Front work light switch, ride control,

double delivery
F4A
5A
Reverse buzzer, gearshift lever
F4B
10 A
Rear hammer button, bucket level

solenoid valve + sensor, clutch
disconnect buttons
F4C
10 A
Backhoe attachment lock, backhoe

attachment travel lock, rear work
light
F5A
15 A
Inner front work lights
F5B
10 A
Low beams
F5C
15 A
Main beams
F6A
7.5 A
Rotating beacon
F6B
7.5 A
(+15) hazard warning lights
F6C
7.5 A
Hand hammer, 4WD
F7A
10 A
(+30) hazard warning lights, horn
F7B
15 A
F7C
6A
F8A
15 A
Outer rear work lights
F8B
15 A
Outer front work lights
F8C
15 A
Inner rear work lights
K11
Forward travel relay
K12
Hazard warning light relay
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COMPONENTS AND CONNECTORS

NAME
DESCRIPTION
NAME
DESCRIPTION
BZ1
Alarm buzzer
KC
Fuse and relay control unit
EV1
Double delivery solenoid valve (optional)
M1
Starter motor
EV2
M10
EV3
Rear hammer solenoid valve (optional)
Air conditioning compressor (not

connected)
EV4
Backhoe attachment travel solenoid

valve
R2
Engine water temperature sender
R3
Fuel level gauge
EV5
Backhoe attachment lock solenoid valve

(optional)
R4
Transmission temperature sender
S2
4WD switch (optional)
EV6
Bucket level solenoid valve
S3
Hand hammer switch (optional)
EV7
Fuel shut off solenoid valve
S4
Double delivery switch (optional)
EV8
4WD solenoid valve (optional)
S5
Ride control switch (optional)
EV9
Reverse travel solenoid valve
S7
Backhoe attachment travel lock switch
EV24
Lifting solenoid valve
S8
EV25
Backhoe attachment lock switch

(optional)
FG1
General fuse 80A
S9
Lights switch
FG2
A/C fuse (not connected)
S11
Front work light switch
H1
Backhoe attachment lock warning light

(optional)
S12
Rear work light switch
S15
Beacon lamp switch
H2
Front left light
S17
Start switch
H3
Front right light
S18
Parking brake switch
H4
Rear left light
S20
Engine oil low pressure switch
H5
Number plate light
S21
Air filter blocked switch
H6
Rear right light
S24
Trasmission oil pressure switch
H11
Outer front left work light
S26
Clutch disconnect button
H12
Outer front right work light
S27
H13
Outer rear left work light
S28
Bucket sensor
H14
Outer rear right work light
S30
Rear hammer pedal (optional)
H15
Rotating beacon
S31
Brake oil level sender
H16
Rotating beacon
S32
Stop light switch
H19
Inner front left work light (optional)
S33
Stop light switch
H20
Inner front right work light (optional)
S40
Gearshift lever
H21
Inner rear left work light (optional)
S41
Light / windshield wiper control lever
H22
Front right work light (optional)
S42
Warning switch
HA1
Reverse buzzer
S44
Pneumo-electric seat (optional)
HA2
Horn
S47
Battery master switch
HA3
Optional buzzer
S48
Cold start temperature switch
K01
Starting relay
S49
K02
A/C relay
Air conditioning pressure switch (not

connected)
K13
Antitheft unit
S52
Solenoid valves lock switch (optional)
S54
Rear horn button (optional)
ST2
Side instrument cluster
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NAME
ST3
DESCRIPTION
NAME
DESCRIPTION
4x1 bucket control lever
X44
Front right work light - 4-way connector
X1
General line - engine line - 18-way

connector
X45
Front right work light (optional) - 4-way

connector
X2
Grid heater - 6-way connector
X46
X3
Engine stop - 1-way connector
Rear left work light (optional) - 4-way

connector
X4
Air filter - 2-way connector
X47
Rear left work light - 4-way connector
X6
Forward gear - 2-way connector
X50
X7
Reverse travel - 2-way connector
Front left work light (optional) - 4-way

connector
X8
General line - rear lights - 12-way

connector
X51
Front left work light - 4-way connector
X61
X10
Solenoid valve line - general line - 29way connector
Light / windshield wiper control lever 12-way connector
X62
Gearshift lever - 6-way connector
X13
General line - front instrument cluster 17-way connector
X63
Number plate light - 2-way connector
X64
Air conditioning compressor - 1-way

connector
X14
Anti-theft device - 11-way connector
X15
Start switch - 10-way connector
X67
Alternator - 3-way connector
X17
Pneumo-electric seat - 4-way connector
X68
X21
Left light / horn - 7-way connector
Engine water temperature switch - 3-way

connector
X22
Right light - 5-way connector
X69
Air conditioning pressure switch - 2-way

connector
X23
Clutch disconnect button - 2-way

connector
X70
Front instrument cluster - 12-way

connector
X24
Backhoe attachment travel lock solenoid

valve - 2-way connector
X71
X25

- 2-way connector
X72
Pilot control line - 1-way connector
X73
X26
Bucket sensor - 3-way connector
Engine oil low pressure switch - 1-way

connector
X27
Horn button on pilot control - 2-way

connector
X80
Beacon lamp - 2-way connector
X81
X28
Clutch disconnect button - 2-way

connector
X82
Control unit - 10-way connector
X83
Relay - 2-way connector
Y29
Bucket level - 2-way connector
X87
X30
General line - left side instrument cluster

line - 13-way connector
X31
Quick coupler solenoid valve - 2-way

connector
X89
Left light - 6-way connector
X101
X32
Rear hammer solenoid valve - 2-way

connector
X104
Valve block switch kit - 1-way connector
X124
Lifting solenoid valve - 2-way connector
X34
Ride control solenoid valve - 2-way

connector
X125
X35
Hand hammer solenoid valve - 2-way

connector
XC1
X36
Rear hammer button - 2-way connector
XC2
X38
Rear right work light - 4-way connector
XC3
X40
Rear right work light (optional) - 4-way

connector
XC4
X41
Blower motor (optional) - 2-way

connector
XA
Start - 1-way connector
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NAME
DESCRIPTION
XC5
XC6
XD
Engine stop diode - 2-way connector
XD1
Parking brake diode - 2-way connector
XST2
Side instrument cluster - 36-way

connector
Y12
Proportional solenoid valves
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ENGINE LINE DIAGRAM
; ;
; ;
;
;;;
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Copyright
10
SOLENOID VALVE LINE DIAGRAM
CB A
S2
A B
S3
S40
II
NO
F
0
R
II
NI
R-N1
M-V1
M-B1
L/G1
N1
X19
G/R1
C1
N1
R-N1
4.4
4.3
5.1
7.1
10
XC4
XC2
11
XC2
XC4
XC1
C1
M-N1
M-B1
L/G1
H-N1
G/R1
M/B1
X13
XC1
XC1
XC1
1.4
F6C
7,5A
+15
+15
F4B
+15
F4A
10A
5A
1.4
K1
86 87a
85
K4
87
86 87a
30
85
K10
87
86 87a
30
85
K11
87
30
86 87a
85
K2
87
86 87a
30
85
87
30
KC
5
XC3
19
XC3 XC3
16
XC3 XC3
XC3
XC6
11
XC6
XC3
L-N1
XC3
C1
L-N1
1.1
10
3.5
C1
17
X1
20
X1
M-B1
X10
7.1
X10
X8
X8
EV2
X35
X28
S26
S27
X23 X23
X26 X26 X26
S28
X29
X29
EV6
M-B1
M-B1
H-R1
R-V1
A-G1
A-R1
B-R1
2
X28
X7
X7
HA1
EV9
X19
X6
X6
EV10
X27
X27
TO PILOT
CONTROL HORN
1.5
N1
N1
N1
N1
N1
N1
N2.5
X19
N1
31
N1
N2.5
EV8
X35
A-R1
B-R1
C-N1
M-V1
M-N1
M-B1
14
M-N1
M-B1
H-R1
R-V1
A-G1
29
X10 X10
A-G1
B-R1
H-N1
11
R-V1
H-R1
X10 X10
R-V1
24
A-R1
B-R1
A-R1
8
X10 X10
A-R1
X10
B-R1
X1
A-R1
18
X1
B-R1
H-N1
M-V1
R-V1
31
3.1
F27480
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11
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12
LIGHT LINE DIAGRAM
Copyright
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REAR LIGHT LINE DIAGRAM
13
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14
Copyright
WORK LIGHT LINE DIAGRAM
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WINDSHIELD WIPER - WASHER LINE DIAGRAM
15
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Copyright
16
HEATER LINE
R-N1
R-N1
1.5
G/N1
G/N1
R-N1.5
R-N1
R-N1
7.5
1.5
12
N1
R-N1
XC6
10
11
XC5
XC6
XC6
X17
S44
+30
4.4
51
+15
5.2
52
KC
7.5
31
F27499
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17
COLD START DIAGRAM
CONTROLLER
2
X83
1
X2
2
X2
N1
10
X82
3
X2
4
X2
L-N1
1
X83
GRID HEATER
8
X82
V-B1
7
X82
S1
6
X82
B-N1
5
X82
M1
4
X82
N1
R1
3
X82
G1
1
X82
5
X2
6
X2
RELAY
TO ENGINE LINE
F27176
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18
SIDE INSTRUMENT CLUSTER
Calibrations
Gage type
Speedometer
Level fuel
Input
Reading
Pointer
tolerance
Input tolerance
Calibration
direction
0 HZ
0 rpm
N/A
Descending
307 HZ
1000 rpm
N/A
60 rpm
Ascending
736 HZ
2400 rpm
N/A
60 rpm
Ascending
240 OHMS
Empty
+0/-6
230-240 OHMS
(REF)
Descending
102 OHMS
1/2 Tank
3 (REF)
98-108 OHMS
Descending
33 OHMS
Full
+4/-2
33-42 OHMS
Ascending
+0/-6
N/A
Descending
111-117 OHMS (REF)
Ascending
900 OHMS
Point B
Transmission
temperature 114 OHMS 106 C (Red/green
line)
Coolant
temperature
VOLT
700 OHMS
Point A
+0/-5
N/A
Descending
95 HMS
106 C (Red/green
line)
93-97 OHMS (REF)
Ascending
11V
Red/green left line
10.7-11.3 V (REF)
Descending
15.9V
Red/green right
line
15.0-15.6 V (REF)
Ascending
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PIN #
NAME
FUNCTION
19
WARNING
LAMP No.
Ignition
10V-16V INPUT
Low oil pressure
Low side switch input
LP1
Air filter restriction
LP2
Parking brake
LP3
Alternator
Alternator D+ input
LP4
Not used
Crab steer
LP6
Neutral
High side switch input
Seat switch
10
A/C system pressure
LP7
11
Not used
12
Driving lights
LP9
13
Not used
14
Not used
15
Engine pre-heat
LP12
16
Not used
17
Direction
LP14
18
Not used
19
Tachometer signal
Alternator w input
20
Fuel level sender
Speed sensor input
21
Water temperature sender
Speed sensor input
22
Speed sensor input
23
Not used
24
Driving lights
LP8
25
Brake
LP28
26
Not used
27
Not used
28
Not used
29
Not used
30
Not used
31
Transmission oil temperature
LP23
32
Not used
33
Front steering
LP25
34
Crab steering
LP26
35
Audible alarm
Open collector output
36
Ground
Ground
LP27
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20
2.2

ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR)
K1
Fuse No. Rating
Function
K2
Parking brake relay
F1A
15 A
Rear windshield wiper and rear

windshield washer
K3
Starting relay
K4
F1B
7.5 A
Engine stop, (+15) anti-theft

device, grid heater
K5
F1C
10 A
Stop light switch
K6
K7
15 A

K8
K9
K10
F2A
F2B
15 A
Air conditioning
F2C
15 A
Pilot control
F3A
3A

F3B
3A

number plate light
F3C
10 A
Front work light switch, ride

control, double delivery
F4A
5A
Reverse buzzer, gearshift lever
F4B
10 A
Rear hammer button, bucket

level solenoid valve + sensor,
clutch disconnect buttons
F4C
10 A
Backhoe attachment lock,

backhoe attachment travel lock,
rear work light
F5A
15 A
F5B
10 A
Low beams
F5C
15 A
Main beams
F6A
7.5 A
Rotating beacon
F6B
7.5 A
F6C
7.5 A
Hand hammer, 4WD
F7A
10 A
(+30) anti-theft device, horn
F7B
10 A
Electrical socket, radio, cab light
F7C
6A
Front windshield wiper
F8A
15 A
F8B
15 A
F8C
15 A
K11
K12
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21

NAME
DESCRIPTION
NAME
DESCRIPTION
BS1
Right speaker (optional)
H21
BS2
Left speaker (optional)
H22
Inner rear right work light (optional)
BZ1
Alarm buzzer
HA1
Reverse buzzer
EV1
HA2
Horn
EV2
HA3
Optional buzzer
EV3
K01
Starting relay
EV4

valve
K02
A/C relay
K13
Antitheft unit
EV5

(optional)
KC
EV6
M1
Starter motor
EV7
M4
Rear windshield wiper motor
EV8
4WD solenoid valve (optional)
M5
Front windshield wiper motor
EV9
M6
Rear windshield washer pump
EV10
Forward speed solenoid valve
M7
Front windshield washer pump
EV11
Ride control solenoid valve (optional)
M9
Blower (optional)
EV24
M10
A/C compressor
EV25
FG1
General fuse 80 A
FG2
A/C fuse 10A
G1
Battery
G2
Alternator
H1

(optional)
H2
Front left light
H3
Front right light
H4
Rear left light
H5
Number plate light
H6
Rear right light
H11
H12
H13
H14
H15
Rotating beacon
H16
Rotating beacon
H17
Current intake illumination
H18
Cab light
H19
H20
R2
R3
Fuel level gauge
R4
S2
4WD switch (optional)
S3
S4
S5
S7
S8
Backhoe attachment lock switch (optional)
S9
Lights switch
S11
S12
S15
Beacon lamp switch
S17
Start switch
S18
S20
S21
S24
S26
S27
S28
Bucket sensor
S30
S31
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22
NAME
DESCRIPTION
S32
Stop light switch
S33
Stop light switch
S34
Left cab light switch
S35
Right cab light switch
S40
Gearshift lever
S41
NAME
DESCRIPTION
X24

X25
Backhoe attachment lock solenoid valve 2-way connector
X26
X27
Pilot control audible alarm button - 2-way

connector
S43
Radio (optional)
X28
Clutch disconnect button - 2-way connector
S44
X29
S45
Blower and air conditioner switch
S46
Current intake
X30
Delivery doubling solenoid valve - 2-way

connector
S47
S48
Grid heater temperature switch
X31

connector
S49
A/C pressure switch
X32
S52

connector
S53
Rear windshield washer + wiper button
X34
Glide ride control solenoid valve - 2-way

connector
S54
ST2
X35

connector
ST3
X36
X1

connector
X37
Rear right light arrangement - 4-way

connector
X2
X38
X3
X39
Rear windshield wiper - 4-way connector
X4
X6
Forward gear - 2-way connector
X40

connector
X7
Reverse travel - 2-way connector
X41
Blower motor (optional) - 2-way connector
X8
General line - rear lights - 12-way connector
X42
X10
Solenoid valve line - general line - 29-way

connector
Front right direction indicator arrangement 4-way connector
X43
X12
General line - upper cab line - 5-way

connector
X44
X45

connector
X46

connector
X13
General line - front instrument cluster - 17way connector
X14
X15
X47
X16
Optional - 1 way connector
X48
X17
Rear left light arrangement - 4-way

connector
X21
Horn/left light - 7-way connector
X49
Front windshield wiper - 6-way connector
X22
X50

connector
X23
Clutch disconnect button - 2-way connector
X51
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Copyright
NAME
DESCRIPTION
NAME
23
DESCRIPTION
X52
Front left direction indicator arrangement 4-way connector
XC5
Control unit - 17-way on-board connector
XC6
X53
Radio (brown) - 8-way connector
XD
X54
Radio (black) - 8-way connector
XD1
X55
Electrical socket - 2-way connector
XST2
Side instrument cluster - 36-way connector
X56
X57
X61
Light / windshield wiper control lever - 12way connector
X62
Gearshift lever - 6-way connector
X63
X64
Air conditioning compressor - 1-way

connector
X67
X68
Engine water temperature switch - 3-way

connector
X69

connector
X70
Front instrument cluster - 12-way connector
X71
X72
Pilot line - 1-way connector
X73

connector
X80
X81
X82
X83
X87
General line - left side instrument cluster

X88
General line - right side instrument cluster

X89
Left light - 6-way connector
X101
X104
X110
Air conditioner - 2-way connector
X111
X124
X125
XA
Horn - 2-way connector
XC1
XC2
XC3
XC4
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24
Copyright
ENGINE LINE DIAGRAM
; ;
; ;
;
;;;
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Copyright
25
CB A
S2
A B
S3
S40
II
NO
F
0
R
II
NI
R-N1
M-V1
M-B1
L/G1
N1
X19
G/R1
C1
N1
R-N1
4.4
4.3
5.1
7.1
10
XC4
XC2
11
XC2
XC4
XC1
C1
M-N1
M-B1
L/G1
H-N1
G/R1
M/B1
X13
XC1
XC1
XC1
1.4
F6C
7,5A
+15
+15
F4B
+15
F4A
10A
5A
1.4
K1
86 87a
85
K4
87
86 87a
30
85
K10
87
86 87a
30
85
K11
87
30
86 87a
85
K2
87
86 87a
30
85
87
30
KC
5
XC3
19
XC3 XC3
16
XC3 XC3
XC3
XC6
11
XC6
XC3
L-N1
XC3
C1
L-N1
1.1
10
3.5
C1
17
X1
20
X1
M-B1
X10
7.1
X10
X8
X8
EV2
X35
X28
S26
S27
X23 X23
X26 X26 X26
S28
X29
X29
EV6
M-B1
M-B1
H-R1
R-V1
A-G1
A-R1
B-R1
2
X28
X7
X7
HA1
EV9
X19
X6
X6
EV10
X27
X27
TO PILOT
CONTROL HORN
1.5
N1
N1
N1
N1
N1
N1
N2.5
X19
N1
31
N1
N2.5
EV8
X35
A-R1
B-R1
C-N1
M-V1
M-N1
M-B1
14
M-N1
M-B1
H-R1
R-V1
A-G1
29
X10 X10
A-G1
B-R1
H-N1
11
R-V1
H-R1
X10 X10
R-V1
24
A-R1
B-R1
A-R1
8
X10 X10
A-R1
X10
B-R1
X1
A-R1
18
X1
B-R1
H-N1
M-V1
R-V1
31
3.1
F27480
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26
Copyright
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Copyright
27
LIGHT LINE DIAGRAM
3.5
N1
L-N1
A1
L1
7.1
7.1
7.1
R1.5
5
X87
X87
X87
V-N1.5
18
6
21
XC4 XC4 XC4
F3B F3A
3A
3A
10
XC1
9
3
XC4 XC4
F6B
11
5.1
10
5.1
7,5A
11
F5B F5C
10A
5
XC4
4
XC4
+15
H/R1
X13
2
XC4
4
XC1
+15
+30
F2A
15A
15A
K5
+
L
2
XC5
10A
L1
5.1
A1
5.1
31
5.1
+30
86 87a
87
C
-
13
XC4
F7A
+15
K12
85
7.1
15
X13
R1.5
H-N1.5
8
16
20
XC4 XC4 XC4
X13
R/N1
13
X13
H1
L-N1
10
XC4
H-R1
B-V1
G1.5
G-N1
3
XC2
X13
R2.5
14
X13
V-N1.5
12
X13
H-L1
B-V1
V1
S31
H/R1
G-R1
S9
R2.5
L1
C BA
L/6
X87
1.5
1.3
6.1
G1.5
R/7
49a/5
A1
30/3
30b/2
H-L1
S42
15/1
49/4
H-N1.5
0 1
1.1
N1
G-R1
H/R1
1.4
51
8.3
50
7.5
30
BZ1
KC
1.4
10
XC3
N1
H-N1
V-N1
A1
X22
G-N1
A1
H1
G1
V1
L1
X101
X101
X101
X101
X101
31
56b
58
H3
56a
56b
X89
58
X89
X89
56a
X89
H2
31
31
X21
3.5
XA
X89
HA2
L1
H1
H-R1
XA
V1
H/R1
7
H/R1
C1
C1
H1
C1
C1
2.5
N1
2.5
F27482
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Copyright
28
2.5
R-N1
4.5
L1
4.5
A1
S32
S33
19
XC4
XC5
XC5
XC5
XC5
XC1
XC1
R-N1
R-N1
B/R1
G1
A1
L1
17
XC4
G-N1
L1
A1
R1
XC1
17
XC5
F1C
10A
+15
4.2
11
4.2
10
52
8.3
KC
12
L1
A1
XC3
20
21
XC3
XC3
R-N1
13
XC3
G1
XC3
X42
N1
X48
G1
A1
N1
A1
L1
4
X52
R-N1
X37
N1
N1
R-N1
X8
G-N1
N1
L1
R-N1
R-N1
59c
A1
G1
G1
A1
10
H6
N1
X63
N1
31
59c
58
31
4.5
H5
31
X63
H4
58
G-N1
N1
N1
R-N1
G-N1
8.3
N1
R-N1
2
G-N1
G-N1
5
G-N1
L1
L1
G1
31
6.1
F27483
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Copyright
29
A B
S12
N1
N1
7.1
C/B1
Z-N1
1
11
87
13
15
XC5
86 87a
85
K7
87
F8A
86 87a
+15
15A
K9
87
85
H-N1
F4C
15A
30
XC3
+30 10A
F8C
15A
18
XC5
+30
F8B
K8
11
XC3
+30
15A
30
14
XC3
V1
12
XC5
F5A
86 87a
C/B1
Z-N1
4
XC3
+30
85
X87
H1
14
XC5
Z-N1
S-G1
3
XC3
X87
S-G1
X87
K6
7.1
N1
S-G1
4.5
C/N1
V-N1
A B
S11
C/N1
C/B1
3.5
86 87a
30
87
85
30
KC
H11
5.5
31
X51
H19
X50
H12
X44
H20
X45
H13
X47
H21
X46
H14
V-N1
H-N1
N1
H-N1
N1
H1
N1
V1
H1
C/B1
N1
3.5
X38
X40
H22
31
7.1
F27484
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Copyright
30
WINDSHIELD WASHER/WIPER LINE DIAGRAM
6.5
R-N1
C/N1
2 1 0
0 12
S41
56b
56a
56
54S 54D
30
53 31b
H15
49
15
R
0
L
11
A-V1.5
10
12
X61
X80
X80
M1
X81
X81
HA3
X43
C-N1
1.5
A-G1.5
A/B1
R/N1
N1
XC5
2.5
X13
C1
X13
XC5
XC5
14
XC4
15
XC4
12
XC4
XC4
XC2
16
XC5
XC2
XC2
C/N1
C/N1
9
X88
X13
X87
C/N1
C/N1
X88
C-N1
L-B1
A/B1
A/R1
2
X88
Z1
X88
Z1
X88
A-G1.5
X88
A-V1.5
12
X87
L/B1
A/N1
N1
C-N1
A-G1.5
A1
L-N1
L1
A/N1
A/R1
A/B1
N1
G/R1
6.5
V-N1.5
N1
N1
A1
L-N1
L1
G/R1
V-N1.5
H16
31
S15
3.5
3.5
4.5
4.5
4.5
2.2
4.5
A B
C1
S54
57/58
L1
N1
3.2
S53
8.1
C/N1
XC2
XC3
C1
F7C
F6A
6A A.R.
F3C
7,5A
+15
10A
+15
+15
+15
F1A
15A
4.4
KC
50
M9
53
L-B1
L/B1
3
X39
X57
M6
53a
53b
31b
X57
X56
M7
X56
53
X49
53a
53b
31b
N1
N1
31
N1
N1
N1
N1.5
N1.5
N1.5
N1
31
M5
31
6.5
A/B1
M4
X12
R/N1
X12
A/N1
X41
A/R1
A/N1
-
X41
X12
L-B1
X12
L/B1
X12
A/B1
X10
A/N1
X10
A/B1
A/R1
A/N1
17
XC3
31
8.1
F27485
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Copyright
31
HEATER AND RADIO LINE DIAGRAM
G1
X54
X55
R-N1
N0.5
R0.5
N0.5
R0.5
10
11
X55
1.1
G-V1.5
N1
R-N1
7.5
R-N1
1.5
G-V1.5
A1
S1
V1
X53
B1
G1.5
M-N1
B/R1
N1
N1
R-N1
R-N1
S45
H18
BS1
H1
H17
OFF
0
ON
Z2.5
S46
C1.5
G1
S43
R1.5
5.5
BS2
N4
S34
12
XC6
10
R4
R-N1.5
11
XC6
R-N1
N1
1
S35
X14
Z2.5
1.5
G/N1
R-N1.5
X14
G/N1
XC5
X110
XC6
X111
X17
F7B
S44
10A
+30
4.4
5.2
F2B
15A
+15
51
52
+30
N1.5
KC
7.5
31
F27486
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32
Copyright
COLD START DIAGRAM
CONTROLLER
2
X83
1
X2
2
X2
N1
10
X82
3
X2
4
X2
L-N1
1
X83
GRID HEATER
8
X82
V-B1
7
X82
S1
6
X82
B-N1
5
X82
M1
4
X82
N1
R1
3
X82
G1
1
X82
5
X2
6
X2
RELAY
TO ENGINE LINE
F27176
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Copyright
33
Calibrations
Gage type
Speedometer
Level fuel
Input
Reading
Pointer
tolerance
Input tolerance
Calibration
direction
0 HZ
0 rpm
N/A
Descending
307 HZ
1000 rpm
N/A
60 rpm
Ascending
736 HZ
2400 rpm
N/A
60 rpm
Ascending
240 OHMS
Empty
+0/-6
230-240 OHMS
(REF)
Descending
102 OHMS
1/2 Tank
3 (REF)
98-108 OHMS
Descending
33 OHMS
Full
+4/-2
33-42 OHMS
Ascending
+0/-6
N/A
Descending
111-117 OHMS (REF)
Ascending
900 OHMS
Point B
Transmission
line)
Coolant
temperature
VOLT
700 OHMS
Point A
+0/-5
N/A
Descending
95 HMS
106 C (Red/green
line)
93-97 OHMS (REF)
Ascending
11V
Red/green left line
10.7-11.3 V (REF)
Descending
15.9V
Red/green right
line
15.0-15.6 V (REF)
Ascending
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Copyright
34
PIN #
NAME
FUNCTION
WARNING
LAMP No.
Ignition
10V-16V INPUT
Low oil pressure
LP1
LP2
Parking brake
LP3
Alternator
Alternator D+ input
LP4
Not used
Crab steer
LP6
Neutral
Seat switch
10
A/C system pressure
LP7
11
Not used
12
Driving lights
LP9
13
Not used
14
Not used
15
Engine pre-heat
LP12
16
Not used
17
Direction
LP14
18
Not used
19
Tachometer signal
Alternator w input
20
Fuel level sender
Speed sensor input
21
Speed sensor input
22
Speed sensor input
23
Not used
24
Driving lights
LP8
25
Brake
LP28
26
Not used
27
Not used
28
Not used
29
Not used
30
Not used
31
LP23
32
Not used
33
Front steering
LP25
34
Crab steering
LP26
35
Audible alarm
36
Ground
Ground
LP27
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Copyright
35
AIR CONDITIONER SCHEMATIC
1
30
87a
87
85
86
3
M
Off
Off
Off
4
L
11
10
2
I H ML C
12
5
B
X110
X111
S45
2 1
X111
10 11
X110
+15
S45
+30
X1
pos 8
+15
F27181
Evaporator box
S45
11-way connector
3rd speed relay
Potentiometer
Fuse 25 A
10
Speed switch
Ventilated electrical motor
11
Temperature switch
1 and 2 speed resistor
12
12 V light
Electrical cock
2-way waterproof connection
X111
9-way connector
X110
2-way power connector
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Copyright
36
2.3

ELECTRICAL DIAGRAMS - POWERSHIFT CAB (580SR)

Fuse
No.
Rating
F1A
15 A
F1B
7.5 A
F1C
10 A
F2A
15 A
F2B
F2C
15 A
15 A
F3A
3A
F3B
3A
F3C
10 A
F4A
7.5 A
F4B
10 A
F4C
10 A
F5A
F5B
F5C
F6A
F6B
F6C
15 A
10 A
15 A
15 A
7.5 A
7.5 A
F7A
10 A
F7B
F7C
F8A
F8B
F8C
10 A
6A
15 A
15 A
15 A
Circuit
windshield washer
Engine stop, (+15) anti-theft device,
starter switch key
Stop light switch
Air conditioning
Pilot control
number plate light
double delivery
4WD switch, transmission
disconnect button, EGS power
supply, differential lock switch
solenoid valve + sensor
attachment travel lock
Low beams
Main beams
Rotating beacon
Hand hammer
(+30) hazard warning lights, horn,
(+30) anti-theft device
K2
K3
K4
K5
K6
K7
K8
K9
K10
K12
Forward travel relay, parking brake

Starting relay
Optional
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Copyright
37

NAME
DESCRIPTION
NAME
DESCRIPTION
BS1
HA1
Reverse buzzer
BS2
HA2
Horn
BZ1
Alarm buzzer
HA3
Optional buzzer
EV0
K01
Starting relay
EV1
K02
A/C relay
EV2
K13
Antitheft unit
EV3
K14
Transmission detachment relay
EV4

valve
KC
M1
Starter motor
EV5

(optional)
M4
EV6
M5
EV8
Differential lock solenoid valve
M6
Rear windshield washer pump
EV11
Ride control solenoid valve (optional)
M7
Front windshield washer pump
EV24
Lifting solenoid valve (optional)
M9
Blower (optional)
EV25
Lifting solenoid valve (optional)
M10
A/C compressor
FG1
General fuse 80 A
FG2
A/C fuse 10A
G1
Battery
G2
Alternator
H1
H2
Front left light
H3
Front right light
H4
Rear left light
H5
Number plate light
H6
Rear right light
H11
H12
H13
H14
H15
Rotating beacon
H16
Rotating beacon
H17
Current intake illumination
H18
Cab light
H19
H20
H21
H22
Inner rear right work light (optional)
R2
R3
Fuel level gauge
R4
Transmission oil high temperature sender
S2
4WD switch
S3
S4
S5
S7
S8
Backhoe attachment lock switch (optional)
S9
Lights switch
S11
S12
S15
Beacon lamp switch
S17
Start switch
S18
S20
S21
S24
S26
S28
Bucket sensor
S29
Front horn button
S30
S31
S32
Stop light switch
S33
Stop light switch
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Copyright
38
NAME
DESCRIPTION
S34
Left cab light switch
S35
Right cab light switch
S36
NAME
DESCRIPTION
X25
A/C pressure switch
X26
S41
X27
S42
Warning switch
Pilot control audible alarm button - 2-way

connector
S43
Radio (optional)
X28
Clutch disconnect button + differential lock

switch - 4-way connector
S44
X29
S45
Blower and air conditioner switch
X30
S46
Current intake
Delivery doubling solenoid valve - 2-way

connector
S47
Differential lock switch
X31
S48
EGS manual - Auto switch

connector
S49
X32
S50
EGS

connector
S52
X33
Differential lock solenoid valve - 2-way

connector
S53
Rear windshield washer + wiper switch
X34a
S54
Ride control solenoid valve - 2-way

connector
S68
Cold start temperature switch
X35
ST2
Front instrument cluster

connector
ST3
X36
X1

connector
X37
Rear right light arrangement - 4-way

connector
X2
X38
X3
X39
X4
X40
X7
Reverse travel buzzer - 2-way connector

connector
X9
General line - front instrument cluster line 13-way connector
X41
Blower motor (optional) - 2-way connector
X42
X10
Solenoid valve line - general line - 29-way

connector
Front direction indicator arrangement - 4way connector
X43
X12
General line - upper cab line - 5-way

connector
X44
X45

connector
X46

connector
X13
General line - front instrument cluster line 17-way connector
X14
X15
X47
X16
Optional - 1 way connector
X48
X17
Rear left light arrangement - 4-way

connector
X21
Left light / horn - 7-way connector
X49
X22
X50

connector
X23
EGS - 9-way connector
X24

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Copyright
NAME
DESCRIPTION
NAME
39
DESCRIPTION
X51
XC4
X52
Front left direction indicator arrangement 4-way connector
XC5
XC6
X53
Radio (brown) - 8-way connector
XD
X54
Radio (black) - 8-way connector
XD1
X55
Electrical socket - 2-way connector
XST2
X56
X57
X61
Light / windshield wiper control lever - 12way connector
X63
X64
Conditioner (optional) - 1-way connector
X67
X70
X71
X72
Pilot control - 1-way connector
X73

connector
X80
X81
X82
X83
X84
Gearshift extension - 13-way connector
X85
Gearshift - 12-way connector
X87
General line - side instrument cluster line 13-way connector
X88
General line - side instrument cluster line 9-way connector
X89
Front left light - 6-way connector
X102
X103
X104
X110
X111
X124
X125
XA
XC1
XC2
XC3
Y12
Proportional solenoid valves
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40
ENGINE LINE DIAGRAM
Copyright
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Copyright
41
R-N1
N1
C1
B-R1
4
H J
X83
B0.5
R0.5
B-V0.5
G0.5
H-L1
B-R1
X13
XC2
X23
11
XC2
XC4
11
4.1
XC1 XC1 XC1
F6C
70
+15
F4A
+15
7.5A
XC1
1.4
F4B
10A
1.4
K2
K4
85
XC1
5.2
+15
K10
86 87a
XC1
7,5A
X13
M-B1
A-B1
C1
B-R1
C-L1
7.1
H-N1
M/B1
7
19
G/R1
XC4
Z/N1
M-N1
X13 X13
M-V1
87
30
A-B1
87a
86
17
B-R1
X13 X13
18
A-R1
85
20
B-R1
K14
10
EGS
S50
B-M0.5
M0.5
S48
H0.5
S29
N0.5
A B
6
Z0.5
S0.5
B-S0.5
H-B0.5
S3
L-B0.5
A B
L0.5
B-G0.5
N1
S2
V0.5
Z/N1
CB A
5.1
4.1
4.4
87
86 87a
30
87
85
86 87a
30
85
87
30
KC
20
X10
V0.5
H-N1
C-L1
EV8
X33
X33
EV2
X35
X35
N1
X32
X28
X32
X28
X28
X26 X26 X26
S28
X85
C1
H-R1
R-V1
A-G1
A-R1
R-V1
B-R1
X36
EV3
X84
X1
R-V1
2
X36
S30
12 13
17
X1
H-R1
X1
G0.5
X10
B-V0.5
H-R1
11
10 11
M-B0.5
29
X10 X10
Z0.5
26
X10
7.1
N0.5
21
X10
C1
XC6
R0.5
28
X10
R-V1
A-G1
H-L1
7
X10
L-N1
XC6
L0.5
12
X10
11
XC3
S0.5
10
X10
XC3
H0.5
18
H-N1
M-V1
R-V1
1.1
X1
XC3
B0.5
16
M0.5
19
XC3 XC3
M-N1
XC3
M-B1
XC3
C1
XC3
X29
X29
X27
X7
X27
EV6
HA1
S26 S47
1.5
31
N1
N1
N2.5
N2.5
N1
N1
X7
31
3.1
F27489
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42
Copyright
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43
LIGHT LINE DIAGRAM
R/N1
S9
2.5
X87
N1
X87
G1.5
C BA
L/6
R1.5
S42
R/7
49a/5
H-N1.5
30/3
30b/2
R2.5
15/1
49/4
0 1
X87
X87
S31
L-N1
V-N1.5
7.1
G-R1
B/R1
5.1
XC1
XC2
18
XC4
F1C
10A
+15
F3B F3A
3A
3A
XC4
21
10
XC4
XC4
XC4
XC4
F6B
11
5.1
10
5.1
7,5A
XC4
16
XC4
F5B F5C
10A
20
XC4
XC4
11
X13
X13
XC4
H/R1
X13
H/R1
H-N1.5
V-N1.5
L-N1
10
XC1
H-R1
H-L1
G1.5
G-N1
8
XC1
X13
B-V1
R/N1
13
1.5
R2.5
12
X13
R1.5
1.5
7.1
1.1
XC4
+15
+30 +15
F2A
15A
K5
+
L
XC5
10A
+30
86 87a
87
51
C
-
XC4
F7A
15A
+15
K12
13
XC1
85
L1
7.1
L1
5.1
A1
5.1
A1
7.1
8.3
30
BZ1
V1
X22
X22
A1
X22
V1
L1
X21
X22
X22
X89
X89
X89
X101 X101 X101 X101 X101
58
56a
H3
56b
56b
X89
31
H-R1
H2
31
31
X21
XA
X89
3.5
X21
XA
HA2
X21
H1
X21
G1
H/R1
7
H/R1
C1
C1
G1
C1
58
2.5
C1
A-B1
7.5
1.5
V1
A-B1
2.3
XC3
50
H1
56a
1.4
10
N1
KC
31
5.1
F27491
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44
2.5
R-N1
4.2
B/R1
4.5
L1
4.5
A1
S32
S33
B/R1
R-N1
L1
A1
R1
19
17
XC4 XC4 XC5 XC5
XC5 XC5
70
2.2
4.2
17
XC1 XC5
71
11
7.5
K11
4.2
10
52
8.3
KC
13
12
20
21
XC3
R-N1
L1
A1
XC3 XC3
G1
XC3 XC3
10
G-N1
31
R-N1
59c
4
X52
4
X48
4
X42
4
X37
N1
G1
A1
H6
31
59c
58
31
4.5
H5
58
N1
G-N1
X63 X63
H4
8.3
N1
G-N1
N1
G-N1
R-N1
L1
X8
G1
R-N1
R-N1
G1
A1
G-N1
G-N1
R-N1
L1
G1
31
6.1
F27492
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45
C/B1
3.5
A B
A B
S12
C/N1
7.1
N1
N1
7.1
N1
S11
C/N1
Z-N1
11
12
X87
X87
X87
N1
Z-N1
X87
C/B1
S-G1
C/B1
N1
S-G1
3.5
C/B1
14
XC3
XC5
12
XC3
14
XC5
13
XC3
15
XC5
11
XC3
18
XC5
XC3
F8B
15A
K6
86 87a
85
87
F8C
15A
K8
30
86 87a
85
K7
87
86 87a
85
V-N1
+15
F8A
15A
30
10A
H-N1
+30
V1
F5A
+30
H1
F4C
+30
+30
15A
K9
87
86 87a
30
85
87
30
KC
5.5
31
N1
H11
X51
H19
X50
H12
X44
H20
X45
H13
X47
H21
X46
H14
V-N1
H-N1
N1
H-N1
N1
H1
N1
V1
H1
C/B1
N1
3.5
X38
X40
H22
31
7.1
F27493
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46
WINDSHIELD WIPER WASHER LINE
R-N1
C/N1
6.5
3.5
A B
10
11
12
X80
X61
X80
X81
X88
X88
X88
X88
L-B1
A/B1
A/R1
A-G1.5
5
L/B1
A/N1
6
X13
X81
HA3
X43
C-N1
1.5
X88
C/N1
R
0
L
R-N1
31
M1
N1
A1
L-N1
L1
G/R1
V-N1.5
X88
21
X13
X13
X87
14
15
12
F7C
16
XC4 XC2 XC5 XC2 XC2 XC2
F6A
6A A.R.
C/N1
Z1
Z1
A-G1.5
XC5 XC5 XC5 XC4 XC4 XC4
A-V1.5
A/B1
A-G1.5
C1
R/N1
2.3
15
S15
6.5
4.5
4.5
4.5
2.1
4.5
A-V1.5
30
A1
56
H16
L1
S41
H15
L-N1
0 12
49
L1
53 31b
A/N1
54S 54D
A/R1
56a
A/B1
2 1 0
6
56b
G/R1
S54
57/58
V-N1.5
S53
8.1
C/N1
XC3
F3C
7,5A
10A
+15
+15
+15
71
5.3
+15
F1A
15A
4.4
KC
50
17
XC3
X12
X12
A/N1
X12
X41 X41
M4
M9
X39
53a
53
53b
31b
X57
M6
X57
X56
M7
X56
X49
53a
53
53b
31b
N1
N1
31
N1
N1
N1
N1.5
N1.5
N1.5
N1
31
M5
31
6.5
A/B1
X12 X12
R/N1
A/N1
X10 X10
31
8.1
F27494
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47
HEATER LINE
G1
X54
X55
R-N1
N0.5
R0.5
N0.5
R0.5
10
11
X55
1.1
G-V1.5
N1
R-N1
7.5
R-N1
1.5
G-V1.5
A1
S1
V1
X53
B1
G1.5
M-N1
B/R1
N1
N1
R-N1
R-N1
S45
H18
BS1
H1
H17
OFF
0
ON
Z2.5
S46
C1.5
G1
S43
R1.5
5.5
BS2
N4
S34
12
XC6
10
R4
R-N1.5
11
XC6
R-N1
N1
1
S35
X14
Z2.5
1.5
G/N1
R-N1.5
X14
G/N1
XC5
X110
XC6
X111
X17
F7B
S44
10A
+30
4.4
5.2
F2B
15A
+15
51
52
+30
N1.5
KC
7.5
31
F27486
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Copyright
COLD START DIAGRAM
CONTROLLER
2
X83
1
X2
2
X2
N1
10
X82
3
X2
4
X2
L-N1
1
X83
GRID HEATER
8
X82
V-B1
7
X82
S1
6
X82
B-N1
5
X82
M1
4
X82
N1
R1
3
X82
G1
1
X82
5
X2
6
X2
RELAY
TO ENGINE LINE
F27176
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49
Calibrations
Gage type
Speedometer
Level fuel
Input
Reading
Pointer
tolerance
Input tolerance
Calibration
direction
0 HZ
0 rpm
N/A
Descending
307 HZ
1000 rpm
N/A
60 rpm
Ascending
736 HZ
2400 rpm
N/A
60 rpm
Ascending
240 OHMS
Empty
+0/-6
230-240 OHMS
(REF)
Descending
102 OHMS
1/2 Tank
3 (REF)
98-108 OHMS
Descending
33 OHMS
Full
+4/-2
33-42 OHMS
Ascending
+0/-6
N/A
Descending
111-117 OHMS (REF)
Ascending
900 OHMS
Point B
Transmission
line)
Coolant
temperature
VOLT
700 OHMS
Point A
+0/-5
N/A
Descending
95 HMS
106 C (Red/
green line)
93-97 OHMS (REF)
Ascending
11V
Red/green left line
10.7-11.3 V (REF)
Descending
15.9V
Red/green right
line
15.0-15.6 V (REF)
Ascending
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50
PIN #
NAME
FUNCTION
WARNING
LAMP No.
Ignition
10V-16V INPUT
Low oil pressure
LP1
LP2
Parking brake
LP3
Alternator
Alternator D+ input
LP4
Not used
Crab steer
LP6
Neutral
Seat switch
10
A/C system pressure
LP7
11
Not used
12
Driving lights
LP9
13
Not used
14
Not used
15
Engine pre-heat
LP12
16
Not used
17
Direction
LP14
18
Not used
19
Tachometer signal
Alternator w input
20
Fuel level sender
Speed sensor input
21
Speed sensor input
22
Speed sensor input
23
Not used
24
Driving lights
LP8
25
Brake
LP28
26
Not used
27
Not used
28
Not used
29
Not used
30
Not used
31
LP23
32
Not used
33
Front steering
LP25
34
Crab steering
LP26
35
Audible alarm
36
Ground
Ground
LP27
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Evaporator box
S45
11-way connector
3rd speed relay
Potentiometer
Fuse 25 A
10
Speed switch
11
Temperature switch
12
12 V light
Electrical cock
X111
9-way connector
X110
51
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52
PILOT SCHEMATIC
B
X23
5
X24
6
X24
1
YP9
P9
3
S1
6
S1
7
S1
PILOT ON/OFF
SWITCH
31
20
X20
21
X20
22
X20
23
X20
1
X14
2
X14
3
X14
4
X14
5
X14
6
X14
1
X4
2
X4
8
S1
2
S2
3
S2
B
X2
1
X27
2
X27
HORN JUMPER
CONNECTION
A
X2
PATTERN
VALVE 2
B
X1
A
X1
PATTERN
VALVE 1
2
X12
1
X12
RH STAB.
PRESS. SW
2
X11
1
X11
LH STAB.
PRESS. SW
C
XR
B
XR
RH STAB.
JOYSTICK
A
XR
C
XL
N1
LH STAB.
JOYSTICK
L
B
XL
N1
4
X24
LEFT
JOYSTICK
N1
5
S1
19
X20
2
YP9
1
2
YP10 YP10
P10 PLUG 10
AUX FORWARD
3
X24
A
XL
PLUG 8
RETRACT
P7
2
X24
2
YP8
PLUG 9
AUX REVERSE
B-R1
1
YP8
P8
2
YP5
N1
1
YP5
PLUG 7
EXTEND
2
YP6
N1
1
YP6
B-R1
2
YP4
1
X24
2
S1
18
X20
N1
17
X20
M-B1
16
X20
L1
15
X20
A1
M-N1
14
X20
B-R1
13
X20
V-N1
2
YP7
V-B1
1
YP7
12
X20
B-G1
11
X20
Z-B1
10
X20
A-N1
9
X20
A-R1
L-G1
G-V1
G-N1
2
YP3
8
X20
P5 PLUG 5
RH DOWN
1
YP4
PLUG 6
RH UP
2
X17
P6
1
X17
H-R1.5
H-G1.5
H-N1.5
H1.5
1
YP3
7
X20
H-N1
5
X13
PLUG 3
LH DOWN
4
X13
P3
3
X13
6
X20
87
MAINFOLD
POWER
2
X13
5
X20
LEFT
JOYSTICK
30
N1
H-R1.5
1
X13
G-R1
87a
85
4
X20
PLUG 4
LH UP
86
3
X20
P4
K1
2
X20
N1.5
H-N1.5
H-G1.5
H1.5
1
X20
L-R1
A
X23
L-B1
1
X72
RIGHT
JOYSTICK
C-N1
LVC
SAFETY
SWITCH
TO SOLENOID
VALVES LINE
7
S2
PATTERN
SWITCH
31
F27182
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Copyright
NAME
DESCRIPTION
K1
Safety relay
S1
Pilot ON/OFF switch - 8-way connector
S2
Gearshift configuration switch - 8-way
connector
X1
Valve configuration 1 - 2-way connector
X2
Valve configuration 2 - 2-way connector
X4
Left hydraulic control lever - 2-way
connector
X11 Left stabilizer pressure switch - 2-way
connector
X12 Right stabilizer pressure switch - 2-way
connector
X13 Right towing line - 5-way connector
X14 Right hydraulic control lever - 6-way
connector
X17 Manifold power - 2-way connector
X20 Control unit - 23-way connector
X23 Safety switch - 2-way connector
X24 Left stabilizer control lever - 6-way
connector
X27 Horn jumper connection - 2-way connector
X72 Pilot control cable - 1-way connector
XL
Left stabilizer control lever - 3-way
connector
XR
Right stabilizer control lever - 3-way
connector
YP3 Left bottom plug 3 - 2-way connector
YP4 Left top plug 4 - 2-way connector
YP5 Right bottom plug 5 - 2-way connector
YP6 Right top plug 6 - 2-way connector
YP7 Extension plug 7 - 2-way connector
YP8 Retraction plug 8 - 2-way connector
YP9 Reverse travel auxiliary speed plug 9 - 2way connector
YP10 Auxiliary forward travel plug 10 - 2-way
connector
53
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2.4
Copyright
ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR+/590SR)

Fuse No. Rating
F1A
15 A
F1B
7.5 A
F1C
10 A
F2A
15 A
F2B
F2C
15 A
15 A
F3A
3A
F3B
3A
F3C
10 A
F4A
5A
F4B
10 A
F4C
10 A
F5A
F5B
F5C
F6A
F6B
F6C
15 A
10 A
15 A
7.5 A
7.5 A
7.5 A
F7A
10 A
F7B
10 A
F7C
F8A
F8B
F8C
6A
15 A
15 A
15 A
Function
windshield washer
Engine stop, (+15) anti-theft
device, grid heater, (+15)
ECU power supply, starter
switch key
Stop light switch
Instrument power supply,
switch lamps, brake oil level
sensor, pneumo-electric seat
Air conditioning
Pilot control
number plate light
Front work light switch, ride
control, double delivery
Forward travel, reverse travel,
reverse buzzer, geashift lever
Rear hammer button, bucket
level solenoid valve + sensor,
clutch disconnect buttons
Backhoe attachment lock,
backhoe attachment travel lock
Low beams
Main beams
Rotating beacon
Hand hammer, 4WD
(+30) hazard warning lights,
horn
Electrical socket, radio, cab
light
K1
K3
K4
K5
K6
K7
K8
K9
K10
K11
K12

Starting relay
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55

NAME
DESCRIPTION
NAME
FG4
DESCRIPTION
Fuse A/C
A1
A2
G1
Battery
A53
Radio (optional)
G67
Alternator
A106
Engine control unit
H7
Reverse buzzer
B107
Water in fuel sensor
H32
Audible alarm
B4
Air filter pressure switch
HA2
Horn
B5
Fuel level sender
K102
Relay for start signal from the control unit
B24
Accelerator knob
K103
Start relay
B25
Foot accelerator
K104
Starter motor relay
B26
Loader bucket sensor
K105
A/C relay
B30
Parking brake
M1
Starter motor
B33
Speed sensor (optional)
M39
B66
Oil temperature switch
M41
Blower motor (optional)
B69
A/C pressure switch
M49
Front pump
B74
Transmission oil pressure switch
M56
B129
Brake oil level sensor
M57
E15
Rotating beacon
M64
A/C compressor
E16
Rotating beacon
S2
4WD switch
E17
Warning lamp for intake
S3
Hand hammer switch
E18
Cab light
S4
Hydraulic speed control switch
E26
Control lock warning lamp
S5
Drive switch
E27
Number plate light
S6
Attachment switch
E28
Rear left light
S8
E29
Rear right light
S9
Lights switch
E38
Rear left work light
S15
Start switch
E40
Rear left light (optional)
S23
Transmission disconnect button
E44
Front right work light
S28
E45
S34
Left door switch
E46
Rear left work light (optional)
S35
Right door switch
E47
S36
Rear hammer button (optional)
E50
Front left work light (optional)
S42
Warning switch
E51
Front left work light
S130
Windshield wiper/washer switch
E121
Front left light/audible alarm
S132
Gear switch
E133
Front right light
S136
Menu scroll switch
F1
Main fuse
S137
F2
Control unit fuse
S138
Rear pump switch
F4
Third speed blower fuse
S139
Display enter switch
F5
Water in fuel fuse
S140
Fuse for anti-theft device, diagnostic

socket, menu scroll switch, display enter
switch, side instrument cluster
S141
F31
S144
Beacon lamp switch
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56
NAME
DESCRIPTION
NAME
X14
DESCRIPTION
SB1
ST1
X15.1
Start - connector
ST3
X15.6
Start - connector
Y6
Forward speed solenoid valve
X17
Optional seat - 4-way connector
Y7
X21
Diagnostics - 10-way connector
Y12
4x1 bucket solenoid valves (optional)
X22
5-way connector
Y24

valve
X23
2-way connector
X24
Accelerator knob - 6-way connector
Y25

valve
X25
Accelerator pedal - 6-way connector
Y26

valve
X26
Loader attachment sensor - 3-way

connector
Y27

valve
X27
X28
Rear left light - 4-way connector
Y30
Hydraulic speed control solenoid valve

(optional)
X29
Rear right light - 4-way connector
X30
Speed control solenoid valve - 2-way

connector
Y32
Y34
Drive control solenoid valve (optional)
X32
Y35
Hand hammer solenoid valve
X33
Speedometer sensor - 2-way connector
X1
Engine line interface - 18-way connector
X34
Drive control - 2-way connector
X2
Preheating relay (optional) - 18-way

connector
X35
Hand hammer button - 2-way connector
X36
X4
Air filter sensor - 18-way connector
X37
X5
Fuel level sensor - 2-way connector
X38
X6
Forward gear solenoid valve - 2-way

connector
X39
Rear windshield wiper motor - 4-way

connector
X7
X40
X8
4WD solenoid valve - 2-way connector
X41
Blower motor - 2-way connector
X10
General line interface - 31-way connector
X42
Right direction indicator - 4-way connector
X12
General cab line interface - 5-way

connector
X43
X44
X13
General line - 17-way connector
X45
Air conditioning - 11-way connector
X14
Antitheft unit
X46
X17
Seat (optional)
X47
X21
Diagnostic
X48
4-way connector
X25
Foot accelerator
X49
6-way connector
X31
Front quick coupler
X50
Front right lights - 4-way connector
X55
Auxiliary 12 V socket
X51
Front left lights - 4-way connector
X72
From pilot control cable
X52
X107
Water in fuel
Front left direction indicator - 4-way

connector
X124
Quick coupler
X53
8-way connector
X128
Optional
X54
Radio - 8-way connector
X55
2-way connector
X56
Windshield wiper pump - 2-way connector
X57
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NAME
DESCRIPTION
X58
Left direction indicator - 4-way connector
X64
Air conditioning switch - 1-way connector
X67
NAME
57
DESCRIPTION
XC5
Fuse and relay control unit line interface general line - 17-way connector
XC6
X69

connector
XST1
X72
3-way connector
XST2
X80
2-way connector
XX
X81
2-way connector
X82
10-way connector
X83
2-way connector
X87
Left general line interface - 13-way

connector
X88
Right side general line interface - 17-way

connector
X106
Engine control unit - 89-way connector
X107
Water in fuel - 3-way connector
X110
X111
X130
12-way connector
X132
6-way connector
X144
2-way connector
X201.P Pilot control - 1-way connector

X201.S Pilot control - 1-way connector
X202
Backhoe attachment travel solenoid valve 2-way connector
X203
X204
Horn switch - 2-way connector
X206
X207
Speed control solenoid valve (optional) - 2way connector
X208
Loader attachment - 2-way connector
X209

connector
X210
Transmissione disconnect - 2-way

connector
XC1
XC2
XC3
XC4
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ENGINE LINE DIAGRAM
Copyright
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Copyright
59
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60
Copyright
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Copyright
LIGHT LINE DIAGRAM
61
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62
Copyright
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Copyright
63
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64
Copyright
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HEATER LINE
65
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Copyright
66
Evaporator box
S45
11-way connector
3rd speed relay
Potentiometer
Fuse 25 A
10
Speed switch
11
Temperature switch
12
12 V light
Electrical cock
X111
9-way connector
X110
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67
Calibrations
Gage type
Speedometer
Level fuel
Input
Reading
Pointer
tolerance
Input tolerance
Calibration
direction
0 HZ
0 rpm
N/A
Descending
307 HZ
1000 rpm
N/A
60 rpm
Ascending
736 HZ
2400 rpm
N/A
60 rpm
Ascending
240 OHMS
Empty
+0/-6
230-240 OHMS
(REF)
Descending
102 OHMS
1/2 Tank
3 (REF)
98-108 OHMS
Descending
33 OHMS
Full
+4/-2
33-42 OHMS
Ascending
+0/-6
N/A
Descending
111-117 OHMS (REF)
Ascending
900 OHMS
Point B
Transmission
line)
Coolant
temperature
VOLT
700 OHMS
Point A
+0/-5
N/A
Descending
95 HMS
106 C (Red/green
line)
93-97 OHMS (REF)
Ascending
11V
Red/green left line
10.7-11.3 V (REF)
Descending
15.9V
Red/green right
line
15.0-15.6 V (REF)
Ascending
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Copyright
68
CONNECTORS
CN2
CN1
PIN
FUNCTION
NOTE
PIN
FUNCTION
Not used
Key on power
Wake up
In gear input
Digital input
Driving lights
Digital input
Front work lights
Digital input
Rear work lights
Digital input
Not used
Not used
Not used
10
Air conditioning
system pressure
Digital input
11
Display input switch
Digital input
12
Enter input switch
Digital input
13
Up input switch
Digital input
14
Down input switch
Digital input
Not used
15
Cranking
Digital input
Not used
16
Digital input
10
Not used
17
Not used
11
Not used
18
Parking brake
12
Not used
19
Not used
20
Idle validation switch
Digital input
21
Decelerator button
Digital input
22
Not used
23
Not used
24
Not used
25
Transmission oil
pressure
26
Not used
Keep alive power

1
2
Can bus input
Twisted pair,
with 120 OHM
terminator
Can bus input
Twisted pair,
with 120 OHM
terminator
Digital input
Digital input
Need to fuse at
1 ampere
without
disconnect
Not used
NOTE
Not used
Audible alarm buzzer
Floyd bell under

80 mA
Starter motor interlock
40 OHM relay =
300 mA
Fuel level gauge
Variable
resistance
14
Transmission
temperature
Thermistor
15
Not used
16
Foot accelerator
0.5-4.5 V
17
Accelerator knob
0.5-4.5 V
Foot accelerator
Output
monitored for
diagnostics
Accelerator knob
Output
monitored for
diagnostics
13
18
19
20
Foot accelerator
21
Accelerator knob
22
Not used
23
Not used
Alternator excitation
24
25
Not used
26
Ground
Low alternator
output signals
fault
Digital input
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2.5
69
ELECTRICAL DIAGRAMS - POWERSHIFT CAB (590SR)

Fuse
No.
Rating
F1A
15 A
F1B
7.5 A
F1C
10 A
F2A
15 A
F2B
F2C
15 A
15 A
F3A
3A
F3B
3A
F3C
10 A
F4A
7.5 A
F4B
10 A
F4C
10 A
F5A
F5B
F5C
F6A
F6B
F6C
F7A
F7B
F7C
F8A
F8B
F8C
15 A
10 A
15 A
15 A
7.5 A
7.5 A
10 A
10 A
6A
15 A
15 A
15 A
Circuit
Rear windshield wiper and rear windshield washer
Engine stop, (+15) anti-theft device,
ECU power supply, starter switch key
Stop light switch
pneumo-electric seat
Air conditioning
Pilot control
Rear right/front left side light, instrument backlighting
Rear left/front right side lights, number
plate light
double delivery
4WD switch, transmission disconnect
button, EGS power supply
solenoid valve + sensor
attachment travel lock
Low beams
Main beams
Rotating beacon
Hand hammer, differential lock
K1A
K3
K4
K5
K6
K7
K8
K9
K10
Flasher
Starting relay
Differential lock relay
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Copyright
70

NAME
DESCRIPTION
NAME
FG4
DESCRIPTION
Fuse A/C
A1
A2
G1
Battery
A23
EGS
G67
Alternator
A53
Radio (optional)
H7
Reverse buzzer
A106
Engine control unit
H32
Audible alarm
A107
HA2
Horn
B4
Air filter switch
K14
Transmission relay
B5
Fuel level sender
K102
B24
Accelerator knob
K103
Start relay
B25
Foot accelerator
K104
Engine start relay
B26
Loader bucket sensor
K105
A/C relay
B30
Parking brake
M1
Starter motor
B66
Transmission oil temperature switch
M39
Rear windshield wiper
B69
A/C pressure switch
M41
B74
M49
B129
M56
Front windshield washer
E15
Rotating beacon
M57
Rear windshield washer
E16
Rotating beacon
M64
A/C compressor
E17
Socket light
S2
4WD switch
E18
Cab light
S3
Hand hammer switch
E27
Number plate light
S4
E28
Rear left light
S5
Drive switch
E29
Rear right light
S15
Start switch
E38
Rear right work light
S23
Differential lock switch
E40
Rear right work light (optional)
S28
E44
S29
Front claxon switch
E45
S34
Left door switch
E46
S35
Right door switch
E47
S36
Rear hammer button
E50
S42
Warning switch
E51
S126
Lights switch
E121
Front left light/horn
S130
Windshield wiper/washer switch
E133
Front right light
S135
F1
General fuse
S136
Menu scroll switch
F2
Power supply fuse
S137
F4
S138
Rear pump switch
F5
Water in fuel fuse
S139

S140
F31
S141
Front work light switches
S160
Rear horn switches
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NAME
DESCRIPTION
NAME
71
DESCRIPTION
SB1
X49
6-way connector
ST1
X50
ST3
X51
X1
General engine line interface - 18-way

connector
X52

connector
X10
X53
8-way connector
X12

connector
X54
X55
2-way connector
X13
X56
X14
X57
X58
Front right light (optional) - 5-way

connector
X15.1
Start connector
X15.2
Start connector
X17
Seat (optional) - 4-way connector
X64
X21
X67
X22
5-way connector
X23
2-way connector
X69

connector
X24
Accelerator knob - 6-way connector
X72
3-way connector
X25
X80
2-way connector
X26
Loader attachment sensor - 3-way

connector
X81
2-way connector
X82
10-way connector
X27
X83
2-way connector
X28
X29
X87

connector
X30

connector
X88

connector
X32
X106
X34
X107
X35
X110
X36
X111
X37
X124
Quick coupler
X38
X128
Optional
X39

connector
X130
12-way connector
X132
6-way connector
X40
X144
2-way connector
X41
X201.P Pilot control - 1-way connector
X42
X201.S Pilot control - 1-way connector
X43
X44
X45
X46
X47
X48
4-way connector
X202

X203

X204
X206
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72
NAME
DESCRIPTION
X207
Speed control solenoid valve (optional) - 2way connector
X208
Loader bucket - 2-way connector
X209

connector
X210
Transmissione disconnect - 2-way

connector
XC1
XC2
XC3
XC4
XC5
XC6
XST1
XST2
Front instrument cluster - 20-way

connector
XX
Pilot control cable
Y8
Differential solenoid valve
Y12
4x1 bucket solenoid valve (optional)
Y24

valve
Y25

valve
Y26

valve
Y27

valve
Y30
Speed control solenoid valve (optional)
Y32
Y34
Y35
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ENGINE LINE DIAGRAM
73
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Copyright
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Copyright
75
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LIGHT LINE DIAGRAM
Copyright
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Copyright
77
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Copyright
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Copyright
79
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80
HEATER LINE
Copyright
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Copyright
Evaporator box
S45
11-way connector
3rd speed relay
Potentiometer
Fuse 25 A
10
Speed switch
11
Temperature switch
12
12 V light
Electrical cock
X111
9-way connector
X110
81
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82
Copyright
Calibrations
GAGE TYPE
FUEL LEVEL
LOW FUEL LAMP

TACHOMETER
COOLANT
VOLT
TRANSMISSION
INPUT
READING
TOLERANCE
320 OHMS
Empty - minimum reading
+0/-2
185 OHMS
Right - edge of red band
3 (Ref)
6.5 OHMS
Full - maximum reading
+4/-0
193 OHMS
ON
5 OHMS
185 OHMS
OFF
5 OHMS
Can message
0-3000 RPM
50 RPM
Can message
Minimum reading 65 C
3 C
Can message
Left edge of red band 106 C
2 C
Can message
Maximum reading 112 C
3 C
11 V
Right edge of lower red band
3 C
16 V
Edge of upper red band
3 C
385 OHMS
3 C
149 OHMS
2 C
112 OHMS
3 C
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Copyright
83
CONNECTORS
CN2
CN1
PIN
FUNCTION
NOTE
PIN
FUNCTION
Not used
Key on power
Wake up
In gear input
Digital input
Driving lights
Digital input
Front work lights
Digital input
Rear work lights
Digital input
Not used
Not used
Not used
10
Air conditioning
system pressure
Digital input
11
Digital input
12
Enter input switch
Digital input
13
Up input switch
Digital input
14
Down input switch
Digital input
Not used
15
Cranking
Digital input
Not used
16
Digital input
10
Not used
17
Not used
11
Not used
18
Parking brake
12
Not used
19
Not used
20
Digital input
21
Decelerator button
Digital input
22
Not used
23
Not used
24
Not used
25
Transmission oil
pressure
26
Not used
Keep alive power

1
2
Can bus input
Twisted pair,
with 120 OHM
terminator
Can bus input
Twisted pair,
with 120 OHM
terminator
Digital input
Digital input
Need to fuse at
1 ampere
without
disconnect
Not used
NOTE
Not used
Floyd bell under

80 mA
40 OHM relay =
300 mA
Fuel level gauge
Variable
resistance
14
Transmission
temperature
Thermistor
15
Not used
16
Foot accelerator
0.5-4.5 V
17
Accelerator knob
0.5-4.5 V
Foot accelerator
Output
monitored for
diagnostics
Accelerator knob
Output
monitored for
diagnostics
13
18
19
20
Foot accelerator
21
Accelerator knob
22
Not used
23
Not used
24
25
Not used
26
Ground
Low alternator
output signals
fault
Digital input
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Copyright
84
2.6
ELECTRICAL DIAGRAMS - 4WS POWERSHIFT CAB (695SR)

K1A
Hazard warning lights
K2A
Buzzer
K3
Starting relay
K4
K5
Steering switch, steering control unit

power supply, stop light switch
K6
K7
Instrument power supply, switch lamps,

brake oil level sensor, pneumo-electric
seat, buzzer
K8
K9
K10
Optional relay
Fuse
No.
Rating
Function
F1A
15 A
Rear windshield wiper and rear windshield washer
F1B
7.5 A
Engine stop, (+15) anti-theft device, (+15)

ECU power supply, starter switch key
F1C
10 A
15 A
F2A
F2B
15 A
Air conditioning
F2C
15 A
Pilot control, loader attachment lamp (optional)
F3A
3A
Rear right/front left side light, instrument

backlighting
F3B
3A
Rear left/front right side lights, number

plate light
F3C
10 A
Front work light switch, ride control, double delivery
F4A
7.5 A
4WD switch, transmission disconnect

button, EGS power supply
F4B
10 A
Rear hammer button, bucket level solenoid valve + sensor
F4C
10 A
Backhoe attachment lock, backhoe attachment travel lock
F5A
15 A
F5B
10 A
Low beams
F5C
15 A
Main beams
F6A
15 A
Rotating beacon
F6B
7.5 A
F6C
7.5 A
Hand hammer
F7A
10 A
F7B
10 A
F7C
6A
F8A
15 A
F8B
15 A
F8C
15 A
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Copyright
85

NAME
DESCRIPTION
A1
A2
A23
EGS
A53
Radio (optional)
A106
Engine control unit
B4
Air filter pressure switch
B5
Fuel level sensor
B24
Accelerator knob
B25
Foot accelerator
B26
Bucket sensor
B30
Parking brake
B66
Oil temperature switch
B69
A/C pressure switch
B74
Transmission oil pressure switch
B97
Rear axle sensor
B98
Front axle sensor
B107
B129
E15
Rotating beacon
E16
Rotating beacon
E17
Warning lamp for intake
E18
Cab light
E26
Control lock warning lamp
E27
Number plate light
E28
Rear left light
E29
Rear right light
E38
Rear right work light
E40
Rear right work light (optional)
E44
E45
E46
E47
E50
E51
E121
Front left light/audible alarm
E133
Front right light
F1
Main fuse
F2
Power supply fuse
F4
F5
Water in fuel fuse
NAME
DESCRIPTION
F31

FG4
Fuse A/C
G1
Battery
G67
Alternator
H7
Reverse buzzer
H32
Audible alarm
HA2
Horn
K14
Transmission relay
K102
K103
Start relay
K104
Starter motor relay
K105
A/C relay
KS
Steering unit
M1
Starter motor
M39
M41
M49
Front pump
M56
M57
M64
A/C compressor
S2
4WD switch
S4
S5
Drive switch
S6
Attachment switch
S15
Start switch
S29
Front claxon switch
S32
Stop light switch
S33
Stop light switch
S34
Left door switch
S35
Right door switch
S36
Rear hammer button
S42
Warning switch
S48
EGS switch
S130
Windshield wiper switch
S132
Steering switch
S135
S136
Menu scroll switch
S137
S138
Rear pump switch
S139
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86
NAME
DESCRIPTION
NAME
DESCRIPTION
S140
X36
S141
Front work light switches
X37
S144
Beacon lamp switch
X38
S160
Rear horn switches
S205
Transmission disconnect switch
X39

connector
SB1
X40
ST1
X41
ST3
X42
X1
General engine line interface - 18-way

connector
X43
X44
X2
Preheating relay (optional) - 2-way

connector
X45
X46
X4
Air filter sensor - 2-way connector
X47
X5
Fuel level sensor - 2-way connector
X48
4-way connector
X6
Forward gear solenoid valve - 2-way

connector
X49
6-way connector
X7
X50
X8
Solenoid valve - 2-way connector
X51
X10
X52

connector
X12

connector
X52
2-way connector
X13
X53
8-way connector
X14
X54
X55
Seat safety switch - 2-way connector
X55
2-way connector
X56
X57
X58
Left direction indicator - 4-way connector
X64
X67
X15.1 Start connector

X15.2 Start connector
X17
Seat (optional) - 4-way connector
X21
X21
7-way connector
X22
Quick coupler
X23
2-way connector
X24
Knob - 6-way connector
X69

connector
X25
X72
3-way connector
X26
Backhoe attachment sensor - 3-way

connector
X80
2-way connector
X27
X81
2-way connector
X28
X82
10-way connector
X29
X83
2-way connector
X30

connector
X87

connector
X32
X88

connector
X34
X106
X35
X107
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NAME
DESCRIPTION
NAME
87
DESCRIPTION
X110
Y94
2WS steering solenoid valve
X111
Y206
X124
Quick coupler
X128
Optional
X130
12-way connector
X132
6-way connector
X144
2-way connector
X202

X203

X204
X208
Loader attachment - 2-way connector
XC1
XC2
XC3
XC4
XC5
XC6
XST1
XST2
XX
Y12
Optional 4x1 bucket solenoid valve
Y24

valve
Y25

valve
Y26

valve
Y27

valve
Y30
Speed control solenoid valve (optional)
Y32
Y34
Y35
Y91
Steering solenoid valve
Y92
4WS steering solenoid valve
Y93
Crab steering solenoid valve
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ENGINE LINE DIAGRAM
Copyright
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Copyright
89
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Copyright
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LIGHT LINE DIAGRAM
91
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Copyright
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Copyright
93
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94
Copyright
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Copyright
HEATER LINE
95
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96
STEERING LINE DIAGRAM
Copyright
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Copyright
Evaporator box
S45
11-way connector
3rd speed relay
Potentiometer
Fuse 25 A
10
Speed switch
11
Temperature switch
12
12 V light
Electrical cock
X111
9-way connector
X110
97
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98
Copyright
Calibrations
GAGE TYPE
FUEL LEVEL
LOW FUEL LAMP

TACHOMETER
COOLANT
VOLT
TRANSMISSION
INPUT
READING
TOLERANCE
320 OHMS
+0/-2
185 OHMS
3 (Ref)
6.5 OHMS
+4/-0
193 OHMS
ON
5 OHMS
185 OHMS
OFF
5 OHMS
Can message
0-3000 RPM
50 RPM
Can message
3 C
Can message
2 C
Can message
3 C
11 V
3 C
16 V
Edge of upper red band
3 C
385 OHMS
3 C
149 OHMS
2 C
112 OHMS
3 C
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Copyright
99
CONNECTORS
CN2
CN1
PIN
FUNCTION
NOTE
PIN
FUNCTION
Not used
Key on power
Wake up
In gear input
Digital input
Driving lights
Digital input
Front work lights
Digital input
Rear work lights
Digital input
Not used
Not used
Not used
10
Air conditioning
system pressure
Digital input
11
Digital input
12
Enter input switch
Digital input
13
Up input switch
Digital input
14
Down input switch
Digital input
Not used
15
Cranking
Digital input
Not used
16
Digital input
10
Not used
17
Not used
11
Not used
18
Parking brake
12
Not used
19
Not used
20
Digital input
21
Decelerator button
Digital input
22
Not used
23
Not used
24
Not used
25
Transmission oil
pressure
26
Not used
Keep alive power

1
2
Can bus input
Twisted pair,
with 120 OHM
terminator
Can bus input
Twisted pair,
with 120 OHM
terminator
Digital input
Digital input
Need to fuse at
1 ampere
without
disconnect
Not used
NOTE
Not used
Floyd bell under

80 mA
40 OHM relay =
300 mA
Fuel level gauge
Variable
resistance
14
Transmission
temperature
Thermistor
15
Not used
16
Foot accelerator
0.5-4.5 V
17
Accelerator knob
0.5-4.5 V
Foot accelerator
Output
monitored for
diagnostics
Accelerator knob
Output
monitored for
diagnostics
13
18
19
20
Foot accelerator
21
Accelerator knob
22
Not used
23
Not used
24
25
Not used
26
Ground
Low alternator
output signals
fault
Digital input
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Copyright
3.
CONTROLS AND INSTRUMENTS
3.1
FRONT CONTROL PANELS (580SR / 590SR)
1
1. 2WD/4WD SWITCH
This switch is used to engage or disengage the
four wheel drive.
This switch has three positions:
- First position (by pushing the
button on
the left):
rear wheel drive with braking on 4 wheels
(lamp off, it turns on when braking).
- Second position (by pushing the
button
on the right):
rear wheel drive with braking on rear wheels
(lamp off).
- Third position (by pushing again the
button on the right):
4 wheel drive with braking on 4 wheels (lamp
on).
NOTE: when the 4WD switch is in OFF position and
the two brake pedals are pressed at the same time,
the 4 wheel drive is engaged automatically (at
speeds higher than 3 km/h) to ensure braking on the
4 wheels; it disengages when the brake pedals are
released.
2. HAND-HELD AUXILIARY HYDRAULIC ATTACHMENT SWITCH (Optional)

This switch has two positions:
- The first position is OFF.
- The second position is ON and enables the
auxiliary hydraulic attachments.
3. OPTIONAL ATTACHMENT SWITCH
4. LOADER ATTACHMENT LOCKING SWITCH
(Optional)
When operated, this switch is for preventing any
movement of the loader attachment during travel.
5. ROTATING BEACON SWITCH
This switch is used to turn the rotating beacon
on or off.
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6. HYDRAULIC SPEED CONTROL SWITCH (If

fitted)
This switch enables an increase in the moving
speed of the loader and backhoe attachment.
7. GLIDE RIDE SWITCH (Optional)
The glide ride system control improves the machine comfort during travel, regardless of the
type of terrain and with the loader bucket full or
empty. It reduces forward and rearward pitching
when moving to the rear or forwards and when
carrying loads, at the same time increasing productivity and operator comfort. It also reduces
impact forces to the machine during operation.
Do not use this system while operating the loader attachment.
S WARNING S
Never operate the glide ride system control when
the loader arm and loader bucket are maintaining
the front of the machine raised off the ground. The
machine could fall and cause serious or fatal injury.
8. MANUAL MODE SELECTION SWITCH
(Powershift transmission)
In situations where manual gearshifting (up or
downshift) is required, the automatic gearshift of
the powershift transmission can be overridden
by means of this switch.
NOTE: changing gears up or down must always be
done using the powershift transmission lever.
When the manual mode is no longer required, place
the switch back to the OFF position to return to automatic gearshifting.
101
9. HORN BUTTON
This hold-down switch operates the warning
horn.
10. HAZARD LIGHT SWITCH
Press the control down to locked position. The
direction indicators and the control will flash simultaneously.
Press the control down again to turn off the direction indicators and the indicator lamp.
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3.2
Copyright
FRONT CONTROL PANELS (695SR)
2
1. 2WD/4WD SWITCH
four wheel drive.
- First position (by pushing the
button on
the left):
rear wheel drive with braking on 4 wheels
(lamp off, it turns on when braking).
- Second position (by pushing the
button
on the right):
rear wheel drive with braking on rear wheels
(lamp off).
- Third position (by pushing again the
button on the right):
4 wheel drive with braking on 4 wheels (lamp
on).
NOTE: when the 4WD switch is in OFF position and
the two brake pedals are pressed at the same time,
the 4 wheel drive is engaged automatically (at
speeds higher than 3 km/h) to ensure braking on the
4 wheels; it disengages when the brake pedals are
released.
2. HAND-HELD AUXILIARY HYDRAULIC ATTACHMENT SWITCH (Optional)

This switch has two positions:
- The second position is ON and enables the
auxiliary hydraulic attachments.
3. LOADER ATTACHMENT LOCKING SWITCH
(Optional)
When operated, this switch is for preventing any
movement of the loader attachment during travel.
4. STEER MODE SWITCH
This switch has a locking cover and is used to
select Road, 4 wheel steer or Crab steer.
- Position (a) = Road
- Position (b) = 4 wheel steer
- Position (c) = Crab steer
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IMPORTANT: before undertaking any road travel,

select Road mode and fold back the cover to lock
the switch in this position.
5. ROTATING BEACON SWITCH
This switch is used to turn the rotating beacon
on or off.
6. HYDRAULIC SPEED CONTROL SWITCH (If
fitted)
This switch enables an increase in the moving
speed of the loader and backhoe attachment.
7. GLIDE RIDE SWITCH (Optional)
The glide ride system control improves the machine comfort during travel, regardless of the
type of terrain and with the loader bucket full or
empty. It reduces forward and rearward pitching
when moving to the rear or forwards and when
carrying loads, at the same time increasing productivity and operator comfort. It also reduces
impact forces to the machine during operation.
Do not use this system while operating the loader attachment.
S WARNING S
Never operate the glide ride system control when
the loader arm and loader bucket are maintaining
the front of the machine raised off the ground. The
machine could fall and cause serious or fatal injury.
103
8. MANUAL MODE SELECTION SWITCH

In situations where manual gearshifting (up or
downshift) is required, the automatic gearshift of
the powershift transmission can be overridden
by means of this switch.
NOTE: changing gears up or down must always be
done using the powershift transmission lever.
When the manual mode is no longer required, place
the switch back to the OFF position to return to automatic gearshifting.
9. HORN BUTTON
horn.
10. HAZARD LIGHT SWITCH
Press the control down to locked position. The
direction indicators and the control will flash simultaneously.
Press the control down again to turn off the direction indicators and the indicator lamp.
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3.3
Copyright
SIDE INSTRUMENT CLUSTER PANEL (580SR)
3
1. FRONT WORK LIGHT SWITCH
- Second position, the two front external work
lights turn on.
- Third position, the two front internal work
lights turn on.
The light switch turns on only in the second
and third position.
2. LIGHT SWITCH
- The second position powers the gauge cluster, the parking lights, with heading indicator
lamp and the rear red lateral lights.
- The third position enables the main beams
and the indicator lamp of the main beams.
3. ROLL-OVER PROTECTION SWITCH (Optional)
roll-over protection device. When the operator is
about to start working with the backhoe attachment in conditions which could cause the machine to roll over, he/she must activate the rollover protection device by pressing the switch
(ON position and lamp turned on).

In this condition, the audible alarm will sound by
means of the buzzer when the pressure switch,
installed on the backhoe attachment boom cylinder, detects a pressure exceeding the following values:
2WS = 116 bar (17 psi)
4WS = 126.5 bar (18 psi)
4. BACKHOE ATTACHMENT SIDESHIFT CARRIAGE LOCKING / UNLOCKING SWITCH
(Sideshift version)
The switch is used to lock or unlock the backhoe
attachment sideshift carriage to allow sideshifting.
5. REAR WORK LIGHT SWITCH
- The first position is OFF, the rear lights are
off.
- Second position, the two rear external work
lights turn on.
- Third position, the two rear internal work
lights turn on.
The light switch turns on only in the second and
third position.
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NOTE: never use the work lights during road travel.

6. SIDE INSTRUMENT CLUSTER
7. REAR WINDSHIELD WIPER SWITCH
When this switch is pressed, the windshield wiper is activated and will continue operating until
the switch is returned to the OFF position.
8. REAR WINDSHIELD WASHER SWITCH
The windshield washer will operate when this
switch is pressed and held down.
When the switch is released, the windshield
washer ceases to operate.
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3.4
Copyright
SIDE INSTRUMENT CLUSTER PANEL (580SR+ / 590SR / 695SR)
4
1. FRONT WORK LIGHT SWITCH
- Second position, the two front external work
lights turn on.
- Third position, the two front internal work
lights turn on.
The light switch turns on only in the second
and third position.
2. LIGHT SWITCH
- The second position powers the gauge cluster, the parking lights, with heading indicator
lamp and the rear red lateral lights.
- The third position enables the main beams
and the indicator lamp of the main beams.
3. ROLL-OVER PROTECTION SWITCH (Optional)
roll-over protection device. When the operator is
about to start working with the backhoe attachment in conditions which could cause the machine to roll over, he/she must activate the roll-
over protection device by pressing the switch

(ON position and lamp turned on).
In this condition, the audible alarm will sound by
means of the buzzer when the pressure switch,
installed on the backhoe attachment boom cylinder, detects a pressure exceeding the following values:
2WS = 116 bar (17 psi)
4WS = 126.5 bar (18 psi)
4. BACKHOE ATTACHMENT LOCKING SWITCH
(Optional)
attachment locking plate in preparation for road
travel.
5. REAR WORK LIGHT SWITCH
- The first position is OFF, the rear lights are
off.
- Second position, the two rear external work
lights turn on.
- Third position, the two rear internal work
lights turn on.
The light switch turns on only in the second and
third position.
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NOTE: never use the work lights during road travel.

6. SIDE INSTRUMENT CLUSTER
7. HORN BUTTON
horn.
8. UP/DOWN SWITCH
By means of this control, it is possible to scroll
through the menu or data options shown on the
diagnostic display.
9. MENU ENTER SWITCH
By means of this control it is possible to display
and confirm the menu options shown on the display.
10. REAR WINDSHIELD WIPER AND WASHER
SWITCH
When this switch is pressed, the windshield wiper is activated and will continue operating until
the switch is returned to the OFF position.
The windshield washer is operated by further
pressing and holding the switch.
When the switch is released, the washer stops
and the wiper starts operating again.
11. BACKHOE ATTACHMENT SIDESHIFT CARRIAGE LOCKING / UNLOCKING SWITCH
(Sideshift version)
attachment sideshift carriage to allow sideshifting.
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3.5
Copyright
SIDE INSTRUMENT CLUSTER (580SR)
1. BRAKE LIQUID LEVEL WARNING LAMP

This lamp turns on and the audible warning device sounds when the brake liquid is at minimum
level.
2. SIDE LIGHT AND LOW BEAM INDICATOR
LAMP
This indicator lamp turns on when the side lights
or the low beams are on.
3. MAIN BEAM INDICATOR LAMP
This indicator lamp turns on when the main
beams are on.
4. DIRECTION INDICATOR LAMP
This lamp turns on when the direction indicators
are working.
5. AIR CONDITIONER INDICATOR LAMP (Optional)
This lamp turns on when the air conditioner is
working.
5
6. ENGINE OIL PRESSURE WARNING LAMP
This warning lamp turns on and the audible
warning device sounds when the engine oil
pressure is too low.
If the lamp turns on while the machine is working, move the machine to a safe place, immediately stop the engine, remove the starter switch
key and find the cause of the problem.
7. GRID HEATER INDICATOR LAMP (If fitted)
If the machine is equipped with a grid heater,
wait for the indicator lamp to turn off before starting the engine.
8. BATTERY CHARGE WARNING LAMP
This warning lamp turns on when the alternator/
fan belt is broken or when the alternator is not
charging the battery.
If the lamp turns on while the machine is working, move the machine to a safe place, immediately stop the engine, remove the starter switch
key and find the cause of the problem.
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9. PARKING BRAKE INDICATOR LAMP

This indicator lamp turns on when the parking
brake lever is in the raised position (wheels
braked).
10. AIR FILTER RESTRICTION WARNING LAMP
This warning lamp turns on when the air filter element needs to be cleaned or replaced.
11. TRANSMISSION OIL PRESSURE WARNING
LAMP
This lamp turns on and the audible alarm
sounds when the transmission oil pressure is
too low. If the lamp turns on while the machine
is working, move the machine to a safe place,
immediately stop the engine, remove the starter
switch key and find the cause of the problem.
12. BATTERY CHARGE GAUGE
This indicator shows the state of charge of the
battery. At normal charge the needle should be
in the grey area. If the needle is in the left red area, this shows that the battery charge is insufficient or that the alternator is not charging the
battery. If the needle is in the right red area, this
indicates excessive battery charge which may
cause damage to the battery.
13. LOW FUEL LEVEL WARNING LAMP
This warning lamp turns on when the fuel level
is low. You have approximately an hour to fill the
fuel tank.
NOTE: when the starter switch key is in the ON position, lamps (6), (8), (9), (10) and (11) turn on for
three seconds. After this time, only lamps (9), (8)
and (11) remain alight. If one or more do not turn on,
the bulbs must be replaced.
14. FUEL LEVEL GAUGE
This gauge shows the quantity of fuel in the fuel
tank.
15. HOURMETER
The hourmeter shows the number of hours and
tenths of hours the engine has been functioning.
It also makes it possible to determine when
servicing operations are due.
109
16. TACHOMETER
The tachometer shows the engine speed in revolutions per minute.
The figures indicated must be multiplied by 100.
Each intermediate mark shows a value of
100 rpm.
We recommend not to reach the red line.
The tachometer shows travel speed in kilometres per hour (km/h) and miles per hour (mph).
Road speed in 4th gear with 18.4-26 tyres.
17. TRANSMISSION OIL TEMPERATURE WARNING LAMP
This indicator shows the transmission oil temperature. When the temperature is normal, the
needle is in the grey area. If the needle is in the
red area, change down to a lower gear. If the
needle still remains in the red area, stop the machine travel, place the gearshift lever and the direction-of-travel control lever in the neutral
position and leave the engine running at
1000 rpm. If this operation does not enable the
oil temperature to be reduced, check the gearbox oil level and make sure that the radiator and
oil cooler are perfectly clean.
18. ENGINE COOLANT TEMPERATURE GAUGE
This indicator shows the temperature of the engine coolant solution. When the temperature is
normal, the needle is in the grey area. If the needle is in the red area, the audible warning
sounds. Move the machine to a safe place, immediately stop the engine, remove the starter
switch key and check the coolant level. Make
sure that the radiator and oil cooler are perfectly
clean and that all the thermostats function correctly.
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3.6
Copyright
SIDE INSTRUMENT CLUSTER (580SR+ / 590SR / 695SR)
1. CAUTION MASTER LAMP

This lamp signals a not critical caution.
When this caution is active, it is necessary to
change the operating mode, plan a down time to
carry out maintenance or, if the fault continues,
consult your dealer.
This warning lamp turns on at the same time of
lamps (5), (9), (11), (13), (14) and (16) that indicates a fault on the machine.
2. SIDE LIGHT AND LOW BEAM INDICATOR
LAMP
This indicator lamp turns on when the side lights
or the low beams are on.
3. MAIN BEAM INDICATOR LAMP
This indicator lamp turns on when the main
beams are on.
4. DIRECTION INDICATOR LAMP
This lamp turns on when the direction indicators
are working.
5. BRAKE LIQUID LEVEL WARNING LAMP
This lamp turns on and the audible warning device sounds when the brake liquid is at minimum
level.
6
6. FOUR WHEEL STEER (4WS) STEER INDICATOR LAMP
This lamp turns on when 4 wheel steer mode is
selected and phased.
7. ROAD (4WS) STEER INDICATOR LAMP
This lamp turns on when 2 wheel steer mode is
selected and phased.
8. CRAB (4WS) STEER INDICATOR LAMP
This lamp turns on when crab steer mode is selected and phased.
NOTE: if the three lamps turn on at once, this
means there is a problem with the electrical circuit.
Consult your Dealer.
9. ENGINE OIL PRESSURE WARNING LAMP
This warning lamp turns on and the audible
warning device sounds when the engine oil
pressure is too low. If the lamp turns on while the
machine is working, move the machine to a safe
place, immediately stop the engine, remove the
starter switch key and find the cause of the problem.
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10. STOP MASTER LAMP

The stop master lamp signals a critical caution.
When this lamp turns on, stop the machine immediately and shut off the engine.
If this is not the case, the machine can get damaged or accidents may occur.
11. BATTERY CHARGE WARNING LAMP
This warning lamp turns on when the alternator/
fan belt is broken or when the alternator is not
charging the battery. If the lamp turns on while
the machine is working, move the machine to a
safe place, immediately stop the engine, remove the starter switch key and find the cause
of the problem.
12. PARKING BRAKE INDICATOR LAMP
This indicator lamp turns on when the parking
brake lever is in the raised position (wheels
braked).
13. AIR FILTER RESTRICTION WARNING LAMP
This warning lamp turns on when the air filter element needs to be cleaned or replaced.
14. TRANSMISSION OIL PRESSURE WARNING
LAMP
This lamp turns on and the audible alarm
sounds when the transmission oil pressure is
too low. If the lamp turns on while the machine
is working, move the machine to a safe place,
immediately stop the engine, remove the starter
switch key and find the cause of the problem.
15. AIR CONDITIONER INDICATOR LAMP (Optional)
This lamp turns on when the air conditioner is
working.
16. GRID HEATER INDICATOR LAMP (If fitted)
If the machine is equipped with a grid heater,
wait for the indicator lamp to turn off before starting the engine.
17. LOW FUEL LEVEL WARNING LAMP
This warning lamp turns on when the fuel level
is low. You have approximately an hour to fill the
fuel tank.
NOTE: when the starter switch key is in the ON position, all lamps turn on and the instrument buzzer
sounds for 5 seconds. Afterwards, the lamps turn off
and only lamp (9) remains on. The gauges (18) and
(19) set to position.
18. FUEL LEVEL GAUGE
This gauge shows the quantity of fuel in the fuel
tank.
111
19. BATTERY CHARGE GAUGE

This indicator shows the state of charge of the
battery. At normal charge the needle should be
in the grey area. If the needle is in the left red area, this shows that the battery charge is insufficient or that the alternator is not charging the
battery. If the needle is in the right red area, this
indicates excessive battery charge which may
cause damage to the battery.
20. DIAGNOSTIC DISPLAY
By means of this display it is possible to visualize the various data of diagnostics. The service
hours are also indicated.
21. TACHOMETER
The tachometer shows the engine speed in revolutions per minute.
The figures indicated must be multiplied by 100.
Each intermediate mark shows a value of
100 rpm.
We recommend not to reach the red line.
22. TRANSMISSION OIL TEMPERATURE WARNING LAMP
This indicator shows the transmission oil temperature. When the temperature is normal, the
needle is in the grey area. If the needle is in the
red area, change down to a lower gear. If the
needle still remains in the red area, stop the machine travel, place the gearshift lever and the direction-of-travel control lever in the neutral
position and leave the engine running at
1000 rpm. If this operation does not enable the
oil temperature to be reduced, check the gearbox oil level and make sure that the radiator and
oil cooler are perfectly clean.
23. ENGINE COOLANT TEMPERATURE GAUGE
This indicator shows the temperature of the engine coolant solution. When the temperature is
normal, the needle is in the grey area. If the needle is in the red area, the audible warning
sounds. Move the machine to a safe place, immediately stop the engine, remove the starter
switch key and check the coolant level. Make
sure that the radiator and oil cooler are perfectly
clean and that all the thermostats function correctly.
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112
3.7

IMMOBILISER CIRCUIT
F28667
A.
B.
C.
D.
M38 Immobiliser
Electronic key socket with LED
2 piece electronic key
+ 50 to ignition
Wire
No.
Function
E. Starter motor
F. + 15 key positive
G. Electronic key
Connection
(+15) Key positive
Connected to the + 12 V full ignition supply
(+30) Permanent + 12 V power supply
Connected to the wire from the battery positive
(-31) Negative power supply
Connected to the vehicle negative at two independent

points
5-6
Immobilization relay No. 2
Connected in line with the wire controlling the starter

motor relay/solenoid - Minimum 500 mA maximum 10 A
capacity
7 - 8 - 9 Immobilization relay No. 1
Connect in line with the wire controlling the ignition or

fuel circuit - Minimum 500 mA maximum 10 A capacity
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4.
DIAGNOSTIC DISPLAY (580SR+ / 590SR / 695SR)
The diagnostics display (1) is located in the middle

of the side instrument panel (4).
The switches used to enter diagnostics are following:
Z UP/DOWN SWITCH (2)

Use this UP/DOWN switch to scroll through the menus.
NOTE: push the arrow at start up to display engine
rpms on the display.
Z DISPLAY ENTER SWITCH (3)

Use this switch to select and confirm a service
menu.
The Diamond icon, or top portion of the switch, is
used to select displays.
The 90 arrow icon or bottom portion of the switch,
is used to enter selected choices.
Features adjustable during setup:
- backlighting dimming and contrast control,
- maintenance/service interval customization;
- storage of error codes;
- grid heater presence:
it is possible to select or deselect the grid heater
option;
- low temperature idle speed setting:
when the engine coolant temperature is below
10 C, the unit will change from a normal low idle
to a low temperature idle which can be adjusted
between 975 and 1500 rpm. The default setting is
1000 rpm;
- high idle speed setting (2500 rpm maximum).
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114
4.1

SYMBOLS
Work hours
Hydraulic oil filter blocked
Maintenance
Transmission oil pressure too high
Maintenance heavy (hours)
Battery charging failure
Maintenance light (hours)
Contaminated fuel
Stored error code
Malfunction
Grid heater
Back-light dimming
Engine speed
Battery voltage too high
Engine area of fault
Battery voltage too low
HEAVY
1000
LIGHT
500
n/min
Engine intake air filter blocked
Charge air temperature too high
Engine coolant level too low
Engine coolant too high
Engine oil pressure too low
Brake fluid level too low
Parking brake engaged
Put the shuttle lever into neutral

position
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4.2
115
SETUP MENU
Dimmer
Increase O
Decrease P
Increase
Decrease
Service
interval
Increase
Decrease
Total no. of pages
CODE
Stored error
code
OCCURRENCE
3-second scroll unless the up/
down button is pressed
Presence of
grid heater
Select / Deselect
Low and high

idle speed
Increase O
Decrease P
Hardware part
number
HARDWARE
P/N
ID
Increase O
Decrease P
Software part
number
HARDWARE
P/N
ID
VER
O Press Enter to make the value flash

and then set up
P Press Enter to make the value stop
flashing
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116
4.3

PROCEDURE ABOUT SELF TEST

Z
Any of the above at with ignition
low
Power up LCD and show work

hours for 10 seconds
Foot max: X.X.

Foot min: X.X.
113/111
range
Go to menu
Normal Key ON
Z

Hand max: X.X. 125/120

Hand min: X.X.
range

Initiate Self test

Foot %: XXX
Hand %: XXX
Any of the above at Key ON
Step 1: Lamps switch on at full intensity.
Step 2: Lamps switch off after 2 seconds.
Check:
100 mA < Current draw < 1amp
10 mA < Current draw < 1 mA
Step 5: Lamps switch off after 2 seconds.
Check:
100 mA < Current draw < 1 A
Step 6: Wait 2 seconds.
Step 8: 2 seconds after maximum angle sweep to red

border.
Step 9: 2 seconds after red-green border is reached move
to second red border for voltage.
Makes sure that needles can

move freely and have proper position
Makes sure that needles are

properly calibrated to applique
Step 10: Park all gauges and start LCD test.
Step 11: When LCD test is complete sound alarm for 2

seconds.
Step 12: The following is shown on the LCD display until the key is turned to OFF or the
cycle ends. All gauges and lamps should work as normal and engine will be able to be
started.
102/92
range
Radiator water
temp. XXX
Air temp. XXX

116/124
range
Brakes: XXX
Engine rpm:
XXXX
117/120
range
Voltage: XX.X
Trans oil temp:
XX

Step 7: Sweep all 5 gauges to maximum angle.
98/88
range
Fuel lvl: XX.X

Fuel tank: XX

10 mA < Current draw < 100 mA
Requested engine rpm: XXX

Step 3: Wait 2 seconds.

Step 4: Instrument backlighting turns on at full intensity.
113/122
range
107/123
range
Engine oil temp:

XXX
Fuel temp: XXX
$
122/126
range
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4.4
117
ON BOARD ERROR CODE RETRIEVAL
MAIN SCREEN
Stored error code
Page 1/6
3059 3-second scroll unless
the up/down button is
OCCURRENCE 3
pressed
CODE
TIME
1004.5
Page 2/6
CODE
3009
OCCURRENCE 2
TIME
1010.6
Page 3/6
Occurrence counter will be incremented on transition from
inactive to active status. Status has to be stored in EEPROM and
checked at key on. Only the hour count of the last occurrence will
be stored per SAE convention.
CODE
1018
OCCURRENCE 1
TIME
1024.5
Page 4/6
CODE
3022
OCCURRENCE 1
HOUR 969
.4
Page 5/6
CODE
3113
OCCURRENCE 2
TIME
1050.6
Page 6/6
CODE
1003
OCCURRENCE 3
TIME
1076.4
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4.5
Copyright
BACKLIGHTING AND DIMMING
A proper and uniform backlighting for matrix, gauge

pointer and symbols shall be provided.
Separate backlighting electronics shall be provided
for matrix and symbols-gauge pointers. The backlighting will be achieved by LEDs and dimming shall
be provided through the setup menu selections.
The backlighting shall go at its maximum level when
the front, rear and driving lights are off.
The gauges backlighting dimming is switched on
when the cluster sees a HIGH level on front work
lights, rear work lights or driving lights for more then
100 ms.
The lamps intensity is decreased when side lights
are activated. The 2 different luminance levels are
defined as 100% during daytime use and 50% when
backlighting is active.
The display intensity of luminance will be 6 cd/m2
(not dimmed). The maximum available luminance
spread will be 30%. To avoid dark zones the maximum difference of intensity of luminance between
closed points is 15%. Note that the matrix backlighting may go to 0 by customer selection. The lamps
and the audible alarm will warn the customer of an
alarm condition occurring.
DIMMING LAW
The dimming adjustment is done through the setup
menu, it can be used in single. In single step mode,
the luminance level go from min to max value in
10 steps.
The luminance levels of display and gauges always
varies in parallel.
The cluster switches between day and night luminance levels using the work and driving light status,
and is able to manage the display and gauges independently using the same law and customer setting.
Only the night settings can be adjusted since the
day setting of the display is 100% intensity.
During dimming setup the matrix shows the dimming symbol together with the percentage of luminance: its value varies using a step of 10%. The
dimming symbol appears when the proper menu is
selected and stays on the matrix for at least 2 seconds.
The dot matrix visualization will be as follows:
The default value is 80% and the may go to zero if

set by the customer.
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4.6
119
WORK HOURS
In order to allow service or the customer to view vehicle hours of operation, it will not be necessary to
have the key. By pressing the enter/display/up/
down switch, with the key-off, the cluster must wake
up and display hours for 10 seconds.
The hourmeter increments when the engine is running (rpm> 600). The hours are visualized starting
from 0.0 until 210,554,060.7 using a step of 6 minutes. In case of battery disconnection, the cluster
can lose 0.1 hour or 6 minutes max.
WORK HOURS SETTING
In order to allow service to install a new Vehicle
Control Module (VCM) on an old vehicle, it is possible to increase (no decrease will be allowed) the
hour to the same setting as the original.
To modify the hourmeter value, execute the following procedure:
Z select the hourmeter function on the display;
Z press and hold depressed for 15 seconds arrow
UP and display until the value shown on display
starts to blink (1 Hz, duty 50%);
Z once in the adjustment mode the meaning of the

arrow UP switch is increase hourmeter value,
and the meaning of arrow DOWN switch is decrease hourmeter value. Single switch pressure
will increase or decrease the value of one unit
(6 min). Continuous switch pressure will increase
or decrease the value continuously (1 every 300
milliseconds): when the value reaches a multiple of
10, the increment/decrement rate is 10 units every
300 ms; when the value reaches a multiple of 100,
the rate is 100 units every 300 ms; when the value
reaches a multiple of 1000, the rate is 1000 units
every 300 ms.
During continuous setting the value stops flashing.
Once the operator has reached the desired value
press and hold down the arrow UP and display
switches for 15 seconds to end setting procedure. It
is not possible to set a value lower than the current
one, and the procedure can be repeated three times
in the cluster life.
Work hours
Any of the above at with ignition low
Power up LCD and show work hours

for 10 seconds
To save the new value
Hourmeter setting
With key to ON press for 15 seconds

Blinking to indicate ability to
edit values
0.1, 1, 10, 100 or 1000 hours

step depending on continuous time pressed
To exit without saving
Value may only increase for the hourmeter. While setting the value it can be decreased due to operator overshoot, but the value can not be stored if it is below the current stored value. Pressing DISPLAY will exit without saving. ENTER must be pressed to store the modified value in protected
memory.
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4.7

FUNCTIONAL DESCRIPTION
Auto wake up at every 600 ms for sensing a change

in ENTER, DISPLAY, UP or DOWN switch status
will be provided. Upon sensing of one of those inputs transition, the cluster has to wake up.
As a general rule, during cranking, all warnings activation and all gauges movements have to be frozen unless we detect an error on the cranking line.
With the key OFF, all indicators must be set to the

parking position. The parking position is hard to obtain with the internal stops of the stepper motor.
With the key ON, follow the procedure below.
Needle collision
control at key-on
At key-on drive all
needles CCW for 1
second
Vibration, service,
transport or battery
loss can generate
a FALSE
If RTZ is observed
on all 5 gauges
TRUE
FALSE
Remove power from gauges:
- engine coolant
- fuel level
Drive gauges until they reach:

- tachometer
- transmission temp
- battery voltage
Drive gauges:
- engine coolant
- fuel level
Start all normal
display functions
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TACHOMETER - ENGINE SPEED GAUGE

The tachometer accuracy should be less than or
equal 50 rpm. The above-specified tolerances
must be respected in all operating ranges (temperature, voltage, etc.). A stepper motor will drive the tachometer. Needle calibration has never to be lost for
any external condition.
The message to be used is EEC1.
EEC1 message
Gauge position
0000
0 rpm
0001 => FFFD
According to the value
Green field
0 - 2500 rpm
Red field
2500 - 3000 rpm
FFFF
0 rpm
The behavior of the gauge in case of faulty sensor

will be to return to the parked position. Since this
signal is a function of the engine controller the appropriate warning lamp and lamp will be illuminated.
During cranking, the needle movement shall be frozen in order to inhibit any spurious movement of it.
ENGINE COOLANT TEMPERATURE GAUGE
A stepper motor will drive coolant temperature
gauge. The gauge accuracy should be less than or
equal 3%. Needle calibration has never to be lost for
any external condition.
Gauge
Temperature
Gauge indication range
+65 to +112 C
Green field
+65 to +106 C
Red field
+106 to +112 C
The message to be used is engine temperature.

Engine temperature
message
Gauge position
00 => FD
According to the logic

above
FE
Minimum value
FF
Minimum value
121
An audible alarm must sound when the engine temperature exceeds 106 C.
If the sender is disconnected, the instrument must
go to 65 C. Once the sensor is connected again,
the instrument must return to the correct position.
Both the movements have to be uniform.
The behavior of the gauge in case of faulty sensor
will be to return to the parked position. Since this
signal is a function of the engine controller the appropriate warning lamp and lamp will be illuminated.
VOLTMETER GAUGE
The voltmeter will indicate the voltage of the vehicle
electrical system. This gauge will have three operating ranges: two reds and one green. One red range
will indicate low voltage. The other red will indicate
high voltage. The green range will indicate normal
operating voltage.
Z The bottom of the scale is 9 V.
Z Low voltage range 11 V or less. The pointer will be
3 of the bold centerline indicating 11 V.
Z The normal operating range will vary between 11
and 16 V.
Z High voltage range 16 V or more. The pointer will
be 3 of the bold centerline indicating 16 V.
Z The top of the scale will be 18 V.
A stepper motor will drive the voltmeter gauge. The
gauge accuracy should be less than or equal 3%.
Needle calibration has never to be lost for any external condition. Loss of voltmeter sensor will be the
loss of the internal VCM A/D converter.
A/D accuracy is specified as 180 mV during self
test operation.
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Copyright
TRANSMISSION OIL TEMPERATURE GAUGE

The oil temp gauge indicates transmission oil temperature from 75 C to 115 C.
This gauge is broken up into two ranges, green and
red. The green zone is 75 C to 106 C.
The red zone is from 105 C to 115.5 C.
This gauge will be connected to a sensor that will
provide a specific resistance to correlate to a specific oil temperature.
Gauge
Temperature
Gauge indication range
+75 to +115 C
Green field
+75 to +105 C
Red field
+105 to +115 C
Z 5 V = 75 C.
The CL of the pointer will be 2 angular degrees of
the centerline of the tick mark that indicates this
temperature.
Z 2.6 V = 93.3 C.
temperature.
Z 2.05 V = 115.5 C.
temperature.
The same range of temperature is used for powershift and powershuttle transmissions. The gauge
will move 9 angular degrees at key-on in the clockwise position to replicate the current production
cluster behavior. This is necessary due to the cool
temperatures present when the unit is working in
backhoe position. In case the sender is disconnected, the gauge has to go down to home position. Reconnecting the sensor will make the error code
inactive and the gauge has to return to the correct
position. Both the movements have to be uniform.
A stepper motor will drive the transmission oil temperature gauge. The gauge accuracy should be less
than or equal 2%. Needle calibration has never to
be lost for any external condition. During cranking,
the needle movement shall be frozen in order to inhibit any spurious movement of it.
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123
FUEL LEVEL GAUGE

When a certain low fuel level is reached, the relevant
low fuel lamp will be lit according to the following
logic. The filtering of the data read is obtained with a
hysteresis on the resistance value joined to a delay
time of 2 seconds.
Ohmic parameter threshold and delay time value
must be kept in NVM. Lamp activation depends on
values used for needle movement; this means that
at key-on the low fuel level warning is active if the
cluster sees a resistance value greater the table below.
Resistance values used are as follows:

The fuel level gauge will indicate the fuel level of the
vehicle tank. The gauge dial will be divided into two
ranges: red and green. The red range will indicate a
low fuel zone. The green range will indicate a nonlow fuel zone. This gauge will be connected to a sensor that will provide specific a resistance to correlate
to a specific fuel tank level.
Tank size
133 l
Empty value (X)

320 ohms
Red-green border
(Y)
186 ohms
Z X = empty. The centerline (CL) of the pointer will be

+0/-2 angular degrees of the centerline of this empty mark.
Z Y = Red - Green threshold. The CL of the pointer
will be +/-3 angular degrees of the centerline of this
1/2 mark.
Z Z = full. The CL of the pointer will be +4/-0 angular
degrees of the centerline of this full mark.
In case the sender is disconnected, the gauge has to
go down in empty position. Reconnecting the sensor
the gauge has to return to the correct position. Both
the movements have to be uniform.
A stepper motor will drive fuel level gauge. The
gauge accuracy should be less than or equal 2%.
Needle calibration has never to be lost for any external condition. During cranking, the needle movement
shall be frozen in order to inhibit any spurious movement of it.
Full (Z) value

6.5 ohms
Fuel level
indicated
30% with 18
angular degrees of
gauge motion
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4.8
Copyright
WARNING SYSTEM
The diagnostic has to inform the operator regarding

all the operating conditions of the loader backhoe
which are out of range. These conditions are different from each other:
Z Warnings
Z Error codes
Z Faults on the system
Z Action Required
1. We can define warnings as all those situations
that could be dangerous for the loader backhoe
or for the operator. The diagnostic will turn the
display Red or as well as activate the buzzer;
the display will show an icon symbol that identifies the occurring problem.
2. There are conditions in which the diagnostic detects one of its sensors out of order: in this case
it will generate an error code. According to the
severity of the failure, it will control the relevant
warning lamp and the audible alarm: the display
will display the appropriate Icon together with
the error code number.
3. If it is necessary to inform the operator that he/
she has done an incorrect maneuver, or that he/
she must perform a special operation (Required
action), the diagnostics will display an icon
again or will activate the relevant audible alarm.
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125
ALARM ACTIVATION
Non Critical
A failure is present but the operator can continue his work: the purpose is to warn him
regarding the presence of the fault. This will be a 1 second beep every 30 seconds.
Critical
A serious fault that can affect either the safety of the operator or the damage of the
loader backhoe is present: the operator shall stop the loader backhoe. This will be a
continuous alarm.
Action Required
The system is asking for a certain maneuver from the operator in order to return to the
normal functionality. This will be a continuous alarm.
Safety
The system purpose is to warn the operator regarding the presence of a dangerous
situation for his safety. This will be a continuous alarm.
General Sound
There are some condition in which there is the need of an activation of the audible
alarm. This is a one second beep to draw the operators attention to the instrument
cluster.
Whenever an audible alarm activation is related to

an icon visualization, this icon should remain displayed at least for 4 seconds in order to give the possibility to the operator to understand the cause of the
alarm activation.
When many warnings with different priority occur,
the audible alarm is related to the higher priority
warning.
When a warning activates with an audible alarm different from the current one, the corresponding icon
must be displayed simultaneously.
If a warning lamp dedicated to a function is associated to the activation cause of the audible alarm, the
warning lamp will activate together with the audible
alarm.
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126
4.9

MAINTENANCE
Two different kinds of maintenance will be available:

Z light maintenance;
Z heavy maintenance.
LIGHT MAINTENANCE
From 2 hours before the set value, display on the
display the light maintenance symbol at every key
on for one second after cranking; after this, the last
selected icon will be visualized on the display. The
hours shown will be the hours when light maintenance is required, not the standard hours displayed
by the hourmeter.
HEAVY MAINTENANCE
From 10 hours before the set value, display on the
display the heavy maintenance symbol at every
key on and should last for one second after cranking. After cranking after this, the last selected icon
will be visualized on the display. The hours shown
will be the hours when light maintenance is required,
not the standard hours displayed by the hourmeter.
HEAVY
1000
Amber-coloured lighting
NOTE: the symbols will show up as follows once the
set value is reached, and the customer clears the
feature with a key cycle.
LIGHT
500
Amber-coloured lighting
DISPLAY FUNCTION
When the hourmeter reaches the light service interval
MAIN SCREEN
3 seconds
LIGHT
3 seconds
500
GREEN
AMBER
Audible alarm for 1 second when displaying either service interval for the first time
When the hourmeter reaches the heavy service interval
MAIN SCREEN
3 seconds
HEAVY
1000
GREEN
AMBER
Audible alarm for 1 second when displaying either service interval for the first time
Since heavy maintenance contains light maintenance the following will be shown:
500 - Light
1000 - Heavy
1500 - Light
2000 - Heavy
The service indicator message will be cleared with a single key cycle
3 seconds
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127
4.10 WARNING MESSAGES

Function Lamp
Engine
coolant too
high
Engine oil
pressure
too low
Transmissi
on oil
pressure
too low
STOP
STOP
Alarm
Lamp
Display
lamp
Condition
DTC
SA
Description Priority Color
Continuous
Coolant
Coolant
temperature
above 112 C 1002 VCM
signal - Above
for 5 seconds
normal
Continuous
Pressure
< 26 bar
500> rpm
Red
Red
Continuous
The engine
Switch
must be
closed to
1008 VCM running with
1
ground for 25
switch closed
seconds
for 25 seconds
Red
STOP
Oil pressure
sensor 3028 ECU
pressure too
low
Malfunction
STOP
Continuous
5 seconds
without
message
1051 ECU
Timeout of
message
Red
Malfunction
STOP
Continuous
25 seconds
without
message
1053 ECU
Timeout of
message
Red
Continuous
5 seconds
without
message
Timeout of
message
1054 VCM
engine
temperature
Red
Malfunction
STOP
Malfunction
STOP
Continuous
5 seconds
without
message
Timeout of
1055 VCM message inlet/ 1
exhaust
Red
Malfunction
STOP
Continuous
5 seconds
without
message
Timeout of
1056 VCM message
engine fluid
Red
Continuous
5 seconds
without
message
Timeout of
message
1057 VCM
vehicle
electrical
Red
Continuous
5 seconds
without
message
Timeout of
1059 VCM message
display
Red
Continuous
Transmission
Transmission
oil above
1009 VCM oil temperature 1
115 C for 5
limit reached
seconds
Red
Malfunction
Malfunction
Transmissi
on oil
temperatur
e too high
STOP
STOP
STOP
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128
Function Lamp
General
display
message
STOP
Alarm
Continuous
One touch
idle active
Lamp
Display
lamp
STOP
Condition
DTC
SA
Only display
with display
request
DTCs 3000 3366
AUTO
Red
N/A
VCM
Red
N/A
This prevents
VCM damaging the
parking brake
Red
n/min
Parking
brake
engaged
Continuous,
if vehicle is
in gear
Switch
closed to
ground
Continuous
Sender
Warns
temperature
customer
1006 VCM
over 152 C
before brake
for 5 seconds
fade
Red
Continuous
Switch
closed to
Vbat for 5
seconds
1007 VCM
Red
Continuous
Pressure
depends on
speed
3032 ECU
Red
3051 ECU
Battery voltage
2
too high
Red
Supply
Supply battery
source above
1014 VCM voltage above 2
16 V for 5
16 V
seconds
Red
Battery voltage
2
too low
Red
Continuous
Supply
Supply battery
source below
1015 VCM voltage below 2
11 V for 5
11 V
seconds
Red
Alternator
unable to
charge
Continuous
Alternator L+
Alternator
terminal
1050 VCM unable to
under 1.5 V
charge
for 5 seconds
Red
Foot
accelerator
signal out
of range
One second
alarm every
30 seconds
IVS not
changing
state in
300 ms
Amber
Brake
temperatur
e too high
Brake fluid
level low
Engine oil
pressure
too high
Battery
charge
voltage too
high
STOP
STOP
Continuous
Battery
charge
voltage too
high
Continuous
Battery
charge
voltage too
low
Continuous
Battery
charge
voltage too
low
3052 ECU
Foot
accelerator
1010 VCM
sensor - not
plausible
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Function Lamp
Alarm
Lamp
Display
lamp
Condition
DTC
SA
129
Foot
accelerator
signal out
of range
One second
alarm every
30 seconds
Foot
Accelerator
accelerator
above 4.75 V 1011 VCM
sensor -signal
for 5 seconds
above range
Amber
Foot
accelerator
signal out
of range
One second
alarm every
30 seconds
Foot
Accelerator
accelerator
under 0.25 V 1012 VCM
sensor -signal
for 5 seconds
below range
Amber
Foot
accelerator
signal out
of range
One second
alarm every
30 seconds
Amber
Foot
accelerator
signal out
of range
One second
alarm every
30 seconds
Foot
Accelerator
accelerator
above 9 V for 1029 VCM sensor 2
5 seconds
shorted high to
Vbat
Amber
Foot
accelerator
signal out
of range
One second
alarm every
30 seconds
Foot
accelerator
Accelerator
under 0.5 V
1030 VCM sensor for 5 seconds
shorted low to
Vbat
Amber
Foot
accelerator
5 V supply
One second
alarm every
30 seconds
Foot
Accelerator
accelerator
2
supply voltage
for 5 seconds
too high
Amber
Foot
accelerator
5 V supply
One second
alarm every
30 seconds
Foot
Accelerator
accelerator
under 4.9 V
1024 VCM
2
supply voltage
for 5 seconds
too low
Amber
Foot
accelerator
5 V supply
One second
alarm every
30 seconds
Foot
Accelerator
accelerator
above 9 V for 1025 VCM
2
supply shorted
5 seconds
high to Vbat
Amber
Foot
accelerator
5 V supply
One second
alarm every
30 seconds
Foot
Accelerator
accelerator
under 0.5 V
1026 VCM supply shorted 2
for 5 seconds
low
to ground
Amber
Foot
accelerator
1013 VCM
sensor -no
signal
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130
Function Lamp
Alarm
Lamp
Display
lamp
Condition
DTC
SA
Hand
accelerator
signal out
of range
One second
alarm every
30 seconds
Hand
Accelerator
accelerator
sensor -signal
for 5 seconds
above range
Amber
Hand
accelerator
signal out
of range
One second
alarm every
30 seconds
Hand
Accelerator
accelerator
under 0.25 V 1036 VCM
sensor -signal
for 5 seconds
above range
Amber
Hand
accelerator
signal out
of range
One second
alarm every
30 seconds
Amber
Hand
accelerator
signal out
of range
One second
alarm every
30 seconds
Hand
Accelerator
accelerator
above 9 V for 1038 VCM sensor 2
5 seconds
shorted high to
Vbat
Amber
Hand
accelerator
signal out
of range
One second
alarm every
30 seconds
Hand
accelerator
Accelerator
under 0.5 V
1039 VCM sensor for 5 seconds
shorted low to
ground
Amber
Hand
accelerator
5 V supply
One second
alarm every
30 seconds
Hand
Accelerator
accelerator
2
supply voltage
for 5 seconds
too high
Amber
Hand
accelerator
5 V supply
One second
alarm every
30 seconds
Hand
Accelerator
accelerator
under 4.9 V
1032 VCM
2
supply voltage
for 5 seconds
too low
Amber
Hand
accelerator
5 V supply
One second
alarm every
30 seconds
Hand
Accelerator
accelerator
above 9 V for 1033 VCM
2
supply shorted
5 seconds
high
Amber
Hand
accelerator
5 V supply
One second
alarm every
30 seconds
Hand
Accelerator
accelerator
under 0.5 V
1034 VCM
2
supply shorted
for 5 seconds
low
Amber
Hand
accelerator
1037 VCM
sensor - no
signal
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Function Lamp
Alarm
Lamp
Display
lamp
Condition
DTC
SA
131
Seat not in
driving
position
Continuous
Switch
closed to
ground with
vehicle in
gear and no
park brake
Boost air
temperatur
e too high
One second
alarm every
30 seconds
Boost
temperature
over
88 C for 5
seconds
Engine
coolant too
high
One second
alarm every
30 seconds
Engine over
Coolant
operating
above 106 C 1019 VCM
coolant
for 5 seconds
temperature
Engine
coolant too
high
One second
alarm every
30 seconds
Transmissi
on oil
above
105 C
This must
have a
VCM debounce time 2
of less then
500 ms
N/A
Engine over
operating
1018 VCM
boost air
temperature
Coolant
temperature
3007 ECU
signal source
high
Amber
Amber
Amber
Amber
One second
alarm every
30 seconds
Coolant
Transmission
above 105 C 1020 VCM over operating 3
for 5 seconds
temperature
Amber
Fuel
temperatur
e too high
One second
alarm every
30 seconds
Fuel over
82 C for 5
seconds
Fuel
temperatur
e too high
Fuel over
1021 VCM operating
temperature
Amber
One second
alarm every
30 seconds
Fuel
temperature
3015 ECU
signal source
high
Amber
Fuel
temperatur
e too high
One second
alarm every
30 seconds
Fuel
temperature
3016 ECU
signal no
signal
Amber
Air filter
restriction
One second
alarm every
30 seconds
Red
Switch
closed to
ground for 5
seconds
1001 VCM
Air filter
threshold
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132
Function Lamp
Alarm
Lamp
Display
lamp
Condition
DTC
SA
Air
conditionin
g not
functional
One second
alarm every
30 seconds
Switch
closed to
Vbat for 5
seconds
Air
conditioning
1003 VCM
system
pressure
Hydraulic
filter
restriction
One second
alarm every
30 seconds
Switch
closed to
ground for 5
seconds
1004 VCM
Fuel
contaminat
ed with
water
One second
alarm every
30 seconds
Display
message
Fuel level
sensor
Amber
Red
1022 VCM
Amber
One second
alarm every
30 seconds
Fuel sender
Fuel sender
above 9 V for 1043 VCM shorted high 5 seconds
park gauge
Amber
Fuel level
sensor
One second
alarm every
30 seconds
Fuel sender
Fuel sender
below 0.5 V
1044 VCM shorted low for 5 seconds
park gauge
Amber
Fuel level
sensor
One second
alarm every
30 seconds
Input is
switched
battery for 5
seconds
Amber
Transmissi
on
temperatur
e sensor
One second
alarm every
30 seconds
Transmission
Transmission
temperature
temperature
sender above 1046 VCM
4
sender shorted
9 V for 5
high
seconds
Amber
Transmissi
on
temperatur
e sensor
One second
alarm every
30 seconds
Transmission
Transmission
temperature
temperature
4
sender below 1047 VCM
sender shorted
0.5 V for 5
low
seconds
Amber
Transmissi
on
temperatur
e sensor
One second
alarm every
30 seconds
Input is
switched
battery for 5
seconds
Amber
Hydraulic filter
threshold
Fuel sender
1045 VCM open circuit park gauge
Transmission
1048 VCM temperature
open circuit
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Function Lamp
Alarm
Lamp
Display
lamp
Condition
DTC
SA
133
Brake
temperatur
e sensor
One second
alarm every
30 seconds
Brake
Sender over
temperature
1000 ohms
1049 VCM
sender out of
for 5 seconds
range
General
display
message
One second
alarm
DTCs 3000 3366
Low fuel
warning
One second
alarm
Amber
Only display
VCM with display
request
Amber
Low fuel must stay on

VCM
for remaining
key cycle
Amber
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Copyright
5.
STARTING SYSTEM
5.1
The system includes a key switch, a reinforcedwiring, a starter motor and a relay-solenoid valve assembly.
This is a starter motor with built-in solenoid and positive engagement drive system.
When the key switch is operated with the forward
and reverse travel lever in the neutral position, the
solenoid windings are energized and cause the mobile core to be drawn inside the solenoid.
This movement causes the drive pinion to mesh with
the ring gear on the engine flywheel. When the ring
gear and the drive pinion are engaged, the mobile
core of the solenoid closes a series of contacts enabling the battery to power the field coils directly and
provide the entire power to the starter motor.
The starter motor contains only a single set of contacts and a mobile core, which closes the contacts
completely, even if the teeth of the drive pinion and
the gear are not aligned. In this case, a spring is
compressed and forces the complete engagement of
the pinion as soon as the starter motor starts rotating.
Once the ignition is turned off, the solenoid and the
starter motor are de-energized. The solenoids recoil
spring causes the drive pinion to be uncoupled and
the contacts of the solenoid to reopen.
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5.2
135
FAULT FINDING
The motor does not start when the starter switch key is operated and the transmission is in the neutral position.
Is the battery properly charged?
YES
NO
Charge or replace the battery
Check the starter motor wiring. Are there bad connections,

YES
cut or stripped cables?
Repair or replace the cables
NO
Is the starter motor seized?
NO
Operate the key switch. Is there a
voltage of +12 V on the (white) wire at
the input of the starter motor solenoid
(terminal 30)?
YES
YES
Repair or replace the starter motor
Does the solenoid YES

make a clicking
NO
Windings, brush or starter

motor mechanism possibly
defective.
NO
Solenoid possibly defective.
Remove the starter motor
and inspect
Check the starter motor relay (K01). Can you

hear the relay operate after operating the
starter switch key?
NO
Remove the connector from the relay (K01). Is there a voltage of
+12 V at terminal 86 (white/black) after the starter switch key is
NO
YES
Replace the relay
Remove the connector from relay K3. Is there a voltage of +12 V

at terminal 86 (white/black) after the reverse travel lever is oper- YES
Replace the relay
Check the starter motor safety relay (K3). Can one hear the relay
operate after operating the reverse travel lever?
NO
NO
Are the cable wires of the reverse travel lever properly conNO
nected?
YES
Does the reverse travel lever switch operate correctly?
Reconnect the wires to the switch
NO
Replace the switch
YES
Are the indicators on the instrument panel correctly lighted
after operating the key switch?
YES
Are the cable wires of the key switch connected correctly?
YES
Replace the key switch.
NO
Check the main power supply

between the battery and the
starter motor key. Pin 2 (red
wire) of the ignition key connector.
NO
Reconnect the wires to the key switch
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CHECKING THE STARTER MOTOR CIRCUIT

To troubleshoot the starter motor circuit rapidly and
easily, it is recommended that a battery-starter motor
testing device (quick discharge) be used, which includes a 0-20 V voltmeter and a 0-500 A ammeter to
detect problems in the starter motor circuit.
Use a testing device in accordance with the manufacturers instructions. If a testing device of the type
indicated is not available, use a standard 0-20 V voltmeter and a 0-500 A ammeter to check the operation
of the starter motor on the vehicle.
Before testing:
Z Check that the battery is properly charged.
Z Check the state of the starter motor circuit, by making sure that no wire is cut or stripped and that the
connections are not loose.
Z Check that the motor is not seized.
Current draw of the starter motor circuit:
1. Disconnect the ground cable (negative) from the
battery (3).
2. Disconnect the positive cable from the battery on
the solenoid of the starter motor. Connect the
positive cable of the ammeter (1) to the positive
terminal of the battery and the negative cable to
the input terminal of the solenoid.
3. Reconnect the ground cable (negative) of the
battery to the negative terminal of the battery.
4. Connect the positive cable of the voltmeter (2) to
the positive terminal of the battery and the negative cable of the voltmeter to the negative terminal of the battery.
5. Disconnect the injection pump fuel inlet cut-off
wire from the solenoid.
6. Start the motor and observe the values indicated
by the voltmeter and ammeter. The voltage must
remain steady at around 12 V with a current
draw of 250 to 300 A.
Z If the current draw is within the indicated range, the
starter motor (4) is operating correctly. If the voltage
reduces during the test, refer to the Resistance of
the starter motor circuit section below.
Z If the current draw is higher than the specified
range, check the circuit as indicated below. If tests
of the starter motor circuit have proved satisfactory,
the starter motor is defective and must be removed
in order to identify the source of the problem.
Z If the current draw is less than the specified range,
the starter motor is defective and must be removed
in order to identify the source of the problem.
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RESISTANCE OF THE STARTER MOTOR

CIRCUIT
(Voltage lowering)
If the current draw is excessive, check the circuit by
noting down the voltage lowers at various components of the circuit.
IMPORTANT: disconnect the injection pump fuel inlet cut-off wire from the solenoid.
Positive cable of the battery:
the positive terminal of the battery (2).
2. Connect the negative cable of the voltmeter (1)
to the battery terminal of the starter motor solenoid valve (3).
3. Start the starter motor and observe the reading
on the voltmeter. If the voltage drop exceeds
0.2 V, check and retighten the cable connections. Check the voltage again. If it is still excessive, replace the cable.
Starter motor connections to ground

the body of the starter motor (2).
to the motor block (3).
0.2 V, check and retighten the cable connections, check the ground connections between
the starter motor clamp and the undercarriage.
Ground cable of the battery:

the motor block (2).
to the negative terminal of the battery (3).
0.2 V, check and retighten the ground cable connections. Check the voltage again. If it is still excessive, replace the ground cable.
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5.3
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STARTER MOTOR
SPECIFICATIONS
Manufacturer .............................................................................................................................................Denso
Voltage .........................................................................................................................................................12 V
Rated power............................................................................................................................................. 2.7 kW
Starting system .......................................................................................................................................Positive
Operating time.............................................................................................................................................. 30 s
Direction of rotation .................................................................................... Clockwise seen from the pinion side
Weight ....................................................................................................................................................... 8.4 kg
Maximum consumption without load at 11 V and 3000 rpm minimum ...................................... 200 A maximum
Maximum consumption with a torque of 19.6 Nm at 8 V and 1130 rpm minimum ................... 600 A maximum
Maximum consumption when shimming at 3 V with a torque of 39.2 Nm minimum ............... 1400 A maximum
MAIN COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Motor
Induction coils
Armature
Commutator
Brush assembly
Pinion gear
Intermediate pinion
Solenoid
Clutch
Drive pinion
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1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
Copyright
Shim
Bearing
Armature
Bearing
Coils housing
Protection
Brush spring
Brush assembly
Disc
Cover
Screw
Screw
Drain
Screw
Protection
Gasket
Washer
Nut
Rod
Connection assembly
Screw
Connection assembly
Nut
Ring
Roller
Cage
Pinion
Ball
Spring
Drain
Screw
Washer
O-ring
Flange
Pinion, rings and spring assembly
O-ring
Bearing
Bearing
Spring
Shaft
Body
Clutch assembly
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REMOVING AND INSTALLING THE STARTER

MOTOR
Z Disconnect the ground cable (negative) from the
battery.
Z Remove the rear protection cover and disconnect
all cables connected to the starter motor.
Z Remove the three retaining screws of the starter
motor and remove the starter motor.
Z To install the starter motor again, proceed in the reverse order to that of removal.
TEST BENCH CHECK

Checking the starter motor without load
NOTE: before carrying out the test, check that the
battery is fully charged then obtain a battery-starter
motor testing device (quick discharge) and a carbon
cell (variable load resistance).
Z Lock the starter motor in a vice with soft jaws.
Z Connect the negative cable (4) of the battery to the
mounting flange of the starter motor.
Z Connect a short cable (6) between the solenoid
battery wire and the terminals of the solenoid
switch.
Z Connect the positive cable of the voltmeter (3) to
the positive terminal of the battery and the negative
cable to the negative terminal of the battery, the
positive cable of the ammeter (1) to the positive terminal of the battery and the negative terminal the
solenoid valve battery or to the starter motor clamp.
Z Install a tachometer (5) at the end of the armature
shaft. Activate the starter motor by adjusting the
carbon cell (2) to obtain a voltage of 11 V. When
the armature is rotating at 3000 rpm, the maximum
current draw must not exceed 200 A.
Z If the starter motor does not operate in these conditions, check that the field coils are not grounded,
that the armature is not rubbing and that its shaft is
not deformed.
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Armature
Z The surface of the commutator must be clean and
without traces of burns. If necessary, remove traces of burns using fine sandpaper. Do not use emery cloth. Then, clean the commutator with a cloth
soaked in gasoline.
Z After rectifying the commutator, polish it with fine
sandpaper, then wipe it with a cloth soaked in
gasoline.
NOTE: make sure not to graze the metal of the commutator during rectification of insulating notches.
Z The resistance of the armature insulation may be
checked by connecting an ohmmeter (1) between
the blades of the commutator (2) and the armature
shaft (3). The resistance must be infinite (no continuity).
Z To check that the armature is not short-circuited, a
special device for armatures must be used. The
other solution is to replace the armature.
Z If the circumference of the armature has come into
contact with the starter pole shoes, the bearings of
the armature are probably excessively worn out.
First check that the starter pole shoes have been
tightened and that the armature rotates without any
concentric defect. If necessary, replace the armature bearings.
Field coils
Z To check the resistance of the field coil insulation,
connect an ohmmeter (1) between the brushes of
each induction coil (2) and a clean unpainted area
of the body (3). The resistance must be infinite (no
continuity).
Z To check the continuity of the field coils, connect an
ohmmeter between the brushes of each induction
coil and the main supply terminal (the thickest
braided wire). The resistance must be equal to 1
MW.
Z If the field coils are defective, the entire assembly
consisting of the body and the field coils must be
replaced.
Drive pinion
Z The drive pinion must only rotate clockwise. If the
pinion is seized or turns in both directions or if its
teeth are damaged, change the complete drive assembly.
NOTE: if the teeth of the drive pinion are damaged,
also check the teeth of the engine flywheel ring gear.
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FAULT FINDING
PROBLEM
The starter motor does not run
(the magnetic switch makes no
operating noise)
The starter motor does not run

(the magnetic switch makes an
operating noise)
CAUSE
CORRECTION
Poor battery specific gravity and

level
Inspect the battery.
Poor ignition switch circuit

connection or contact
Replace the wiring harness and the

ignition switch.
Malfunction of the coil or of the

magnetic switch pull-in piston.
Replace the magnetic switch.
Poor battery specific gravity and

level
Inspect the battery.
Poor start-up circuit contact
Repair the wiring harness.
Poor magnetic switch contact

Motor assembly malfunction (e.g.
layer short, brush wear)
Repair or replace the motor
assembly.
The starter motor runs too slowly
Poor magnetic switch contact

Motor assembly malfunction (e.g.
layer short, brush wear)

Repair or replace the motor
assembly.
Pinion gear does not engage with

ring gear
Repair or replace the clutch and the

control lever.
Clutch sliding
Replace the clutch.
Abnormal bushing wear
Replace the bushing.
Wear on pinion gear or ring gear

tooth tips
Replace the clutch and the ring gear.
Poor pinion gear sliding
Lubricate or replace the clutch.
Pinion gear springing out
Poor ignition switch return
Replace the ignition switch.
Pinion gear disengagement fault

caused by a coil short circuit in
the magnetic switch.
Field coil loss
The starter motor running cannot

crank the engine
Anomalous noise
Magnetic switch coil burnt, etc.
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6.
ALTERNATOR
6.1
SPECIFICATIONS
Manufacturer .............................................................................................................................................Denso
Rated voltage ...............................................................................................................................................12 V
Polarity .................................................................................................................... Negative terminal grounded
Current ........................................................................................................................................................90 A
Minimum charging speed ..................................................................................................................... 1400 rpm
Maximum speed................................................................................................................................... 9000 rpm
Operating temperature ................................................................................................................ -30 C to 90 C
Direction of rotation .................................................................................... Clockwise seen from the pulley side
Regulated voltage at 5000 rpm with 10 A at 25 C .........................................................................14.2 - 14.8 V
Maximum load that can be applied at terminal L.........................................................................12 V, 3.4 W x 6
6.2
The alternator, installed on the motor, on the front

RH side of the vehicle, is driven by the crankshaft
pulley with the help of a belt. The alternator contains
built-in regulators.
Current draw of the starter motor circuit:
When the ignition key is turned, a current of low intensity is sent by the battery to the field winding of
the rotor (terminal IG).
At this stage, the indicator lamp (terminal L) turns on
and the rotor is partially magnetized.
When the motor starts and the partially magnetized
rotor rotates inside the stator, a three-phase alternating current is generated (terminal B+). A constant
portion of this current is transformed into a direct current by three excitation diodes installed in the rectifier.
The direct current is sent as reinforcement through
the field winding of the rotor.
Using this method an increase in the magnetic field
of the rotor is obtained, as well as a rapid rise in the
voltage and current generated at the output.
The luminosity of the indicator lamp decreases when
the voltage generated at the output is increasing (terminal L). The indicator lamp goes out when the voltage at terminal L is equal to that of the battery.
The voltage continues to increase up to the value
predefined by the regulator.
In case the alternator belt is broken, the voltage does
not accumulate in the alternator and the load indicator lamp remains lighted to indicate the problem.
1.
2.
3.
4.
5.
Ground connection
Terminal P: motor tachometer
Terminal L: charge indicator
Terminal B+: charge +12 V
Terminal IG: +12 V after ignition (10 A fuse)
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DIAGRAM OF THE CHARGING CIRCUIT
1.
2.
3.
4.
5.
Alternator
Output winding of the rotor
Rectifier
Regulator
Starter motor
6.
7.
8.
9.
Battery
Key switch
Charge indicator
Speedometer
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6.3
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
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COMPONENTS
Front housing
Rear housing
Rectifier
Brush holder
Regulator
Rear protective
Insulation ring
Insulation ring
Screw
Screw
Nut
Nut
Rotor
Pulley
Pulley nut
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Sealing ring
Sealing ring
Washer
Screw
Electrical terminal
Screw
Bearing
Flange
Flange
Stator
Stud screw
Bearing
Plate
Screw
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6.4
REMOVAL
Electrical disconnections of the alternator

1. Disconnect the negative cable from the battery.
2. Disconnect the battery cable (1) from terminal
B+ (2).
3. Disconnect the connector (3).
Removing the alternator

1. Free the tension roller (1) using a suitable
wrench, then remove the belt (2).
2. Remove the screw (3) and the nut (4).
3. Remove the bolt (5).
4. Remove the alternator.
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PRELIMINARY CHECK AND TESTS
To prevent damage to components of the alternator

charging circuit, the following precautions must be
taken during maintenance:
Z NEVER connect or disconnect a charging circuit
connection, including the battery, when the motor is
running.
Z NEVER dead short to ground any component of the
charging circuit.
Z ALWAYS disconnect the ground cable from the
battery (negative) to recharge the battery on the vehicle using a battery charger.
Z ALWAYS respect the polarity when connecting the
battery on the vehicle or when connecting an auxiliary starter battery to the motor.
IMPORTANT: connect the positive cable to the positive terminal and the negative cable to the negative
terminal.
PRELIMINARY CHECKS
Before undertaking an electrical inspection, check
the charging circuit and the electrical circuit carefully.
Check the state of cables and the tightening of connections.
Checking the battery
Check each cell of the battery with a hydrometer.
The battery must be charged at least 70% and be in
good condition.
Checking the drive belt
Check that the belt and the pulley of the alternator
are clean, without any trace of oil and grease and
that they are in good condition.
Checking the indicator lamp
Turn the ignition key and check that the charge indicator is well lit.
If it is not fully lighted, check its bulb. If the bulb is OK,
check the alternator wire connections as described
in the Preliminary tests section below.
If the indicator lamp is lighted, start the motor and run
it at a speed that is higher than the idling speed. The
indicator lamp must turn off.
If the indicator lamp does not turn off, turn off the motor and disconnect the ground cable L. If the indicator
lamp goes out, an alternator component is defective.
Follow the instructions given in the Checking the alternator components section below.
If the indicator lamp stays lighted, look for a dead
short to ground between the terminal L cable and
the indicator lamp.
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PRELIMINARY TESTS
The preliminary tests may be carried out without removing the charging circuit components, these tests
help check the following items:
Z Connections of the alternator cables
Z Charging current and regulated voltage of the alternator
Z Voltage lowers in the alternator charging circuit
Z Maximum flow of the alternator
Required devices:
Z Voltmeter (0-30 V, moving coil)
Z Millivoltmeter (0-1 V)
Z Ammeter (0-110 A, moving coil)
Z Variable resistance of 1.5 Ohm, 110 A
NOTE: most testing instruments sold in shops group
together several measurement functions in a single
device. Use these devices in accordance with the
manufacturers instructions.
CHECKING THE CONNECTIONS OF THE

ALTERNATOR CABLES
Z Disconnect the terminals B+ (2) and L (3) from the
alternator.
Z Reconnect the battery and turn the ignition key
without starting the motor. Connect a voltmeter (4)
between each terminal (B+ or L) and the ground
(1). The voltmeter must show the battery voltage.
Z If there is no battery voltage, the external cable has
a continuity fault; in this case, check the entire circuit and carry out the necessary repairs.
Z Connect the terminal L indicator lamp wire to the
ground. The indicator lamp should turn on.
Z Disconnect the battery and reconnect the cables to
the alternator.
NOTE: if the indicator lamp does not turn on after
having reconnected the alternator, the regulator of
the alternator or the rotor circuits is defective. Make
sure that terminal L is clean, then check the components of the alternator as indicated in this chapter.
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CHECKING THE CHARGING CURRENT AND

THE REGULATED VOLTAGE
Z Make sure that all electrical components are powered off and that the ignition is turned off (key on
off).
Z Disconnect the negative terminal from the battery
and disconnect terminal B+ (4) from the alternator.
Z Connect an ammeter (1) between the disconnected cable (3) and terminal B+ of the alternator.
Z Connect a voltmeter (2) between terminal B+ of the
alternator and the ground.
Z Reconnect the battery. Start the motor and run it at
a speed of 2000 rpm. Observe the values shown
on the ammeter and the voltmeter.
The voltage shown on the voltmeter should at first be
too high and then should stabilize between 14.214.8 V when the value on the ammeter lowers below
10 A.
If the voltmeter stabilizes at a voltage greater than
14.8 V, the regulator of the alternator needs to be replaced.
On the other hand, if the voltmeter stabilizes below
14.2 V, a component of the alternator is defective or
the resistance in the external connections of the
charging circuit is too high.
If the ammeter indicates zero amps, an alternator
component is defective.
Turn off the motor and carry out the operations described in the Checking the alternator components.
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CHECK THE VOLTAGE LOWERINGS IN THE

CHARGING CIRCUIT
Voltage drop on insulated side
Check that the ignition is turned off (key on off).
Z Disconnect the negative cable from the battery and
disconnect cable B+ (1) from the alternator.
Z Connect a millivoltmeter (4) between the positive
terminal of the battery and cable B+ (5) (positive
side on cable).
Z Connect an ammeter (2) between terminal B+ of the
alternator and cable B+ (negative side on cable).
Z Reconnect the negative cable of the battery and
connect a variable resistance (3) between the battery terminals by adjusting the cursor to the minimum current draw (maximum resistance).
Z Start the motor and increase its speed to 2000 rpm.
Z Gradually reduce the resistance until the ammeter
shows 90 A.
Z Observe the millivoltmeter, which must not indicate
a value that is greater than 400 millivolts.
If the value exceeds 400 millivolts, the resistance of
the external circuit is too high. If the output value of
the alternator is not sufficient and the millivoltmeter indicates a value that is less than 400 millivolts, an alternator component is defective. Carry out the
operations described in the Checking the alternator
components.
Z Stop the engine.
Voltage lower on ground side
Z Check that the ignition is turned off (key on off).
Z Check the same circuit as the one in the previous
test, but by connecting the millivoltmeter (4) between the negative terminal of the battery and the alternator body (negative side on body).
IMPORTANT: make sure that the variable resistance (3) is in the minimum current draw position
(maximum resistance).
Z Start the motor and increase its speed to 2000 rpm.
Z Gradually reduce the resistance until the ammeter
(2) shows 90 A.
Z Observe the millivoltmeter, which must not indicate
a value that is greater than 200 millivolts.
If the value exceeds 200 millivolts, the resistance of
the external circuit is too high.
If the output value of the alternator is not sufficient and
the millivoltmeter indicates a value that is less than
200 millivolts, an alternator component is defective.
Carry out the operations described in the Checking
the alternator components.
Z Stop the engine.
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CHECKING THE MAXIMUM OUTPUT OF THE

ALTERNATOR
Z Check that the ignition is turned off (key on off).
Z Disconnect the negative cable from the battery and
disconnect cable B+ (5) from the alternator.
Z Connect an ammeter (2) between terminal B+ (1)
of the alternator and the disconnected cable B+
(negative side towards the cable).
Z Connect a voltmeter (4) between terminal B+ of the
alternator and the ground.
Z Reconnect the battery, start the motor and increase its speed to 2000 rpm.
Z Gradually reduce the resistance (3) until the ammeter shows 90 A.
Z Observe the voltmeter, which must not indicate a
value that is less than 14.2 V.
If the value lowers below 14.2 V, an alternator component is defective.
Carry out the operations described in the Checking
the alternator components.
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CHECKING THE ALTERNATOR COMPONENTS

Checking of components must be done only if the
PRELIMINARY TESTS reveal an alternator defect
which relates to the following components:
Z Regulator
Z Continuity of the rotor field winding
Z Brushes, springs and slip rings
NOTE: these checks may be carried out without removing the alternator from the vehicle.
The alternator must be removed to check the other
components of the alternator.
Refer to the Removal section in this chapter.
IMPORTANT: before disconnecting the cables from
the alternator, make sure that the ignition is turned
off (key on off) and the negative cable of the battery
is disconnected.
Required devices:
Z 12 V battery
Z Multimeter
Z 2.2 W test lamp
CHECKING THE REGULATOR AND THE FIELD
CIRCUIT OF THE REGULATOR
Z Disconnect all cables from the alternator.
Z Connect a 12 V battery and a 2.2 W test lamp (2) in
series between terminal L (1) and the alternator
body (negative side on body).
Z The test lamp must turn on.
If the lamp does not turn on, the rotor circuit is defective. Check the brushes, the slip rings and the continuity of the rotor field windings.
If the inspection reveals that these components are
in good condition, the defect may be due to the regulator.
CHECKING THE CONTINUITY OF THE ROTOR
FIELD WINDING
Z Remove the regulator with the brush holder.
Z Connect an ohmmeter (3) between the two slip
rings (2). The resistance must be 2.6 ohms at
20 C.
If the resistance is not correct, replace the rotor (1)
as described in the Removal section below.
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RECTIFIER - CHECKING THE POSITIVE /

NEGATIVE DIODES
Check each of the six diodes separately by proceeding as follows:
Z Connect a multimeter (2) in series with one of the
diodes. Place one wire of the multimeter on the
connecting pin (1) of the diode and the other wire
on the plate where the diode is installed.
Z Note down the value of the resistance indicated by
the multimeter. Reverse the wires of the multimeter.
Z The multimeter should indicate infinite resistance
(open circuit) only during the first half of the test. If
this check reveals that a diode is defective, replace
the entire rectifier.
RECTIFIER - CHECKING THE EXCITATION
DIODES
Check each excitation diode separately by proceeding as follows:
Z Connect a multimeter (2) in series on the excitation
diode module. Place the negative wire on terminal
L (1) and the other wire on the connection of each
excitation diode (3).
Z Note down the value of the resistance indicated by
the multimeter. Reverse the wires of the multimeter.
Z The multimeter should indicate infinite resistance
(open circuit) only during the first half of the test. If
this check reveals that a diode is defective, replace
the entire rectifier.
STATOR - CHECKING THE CONTINUITY OF THE
WINDING
Check each excitation diode separately by proceeding as follows:
Z Connect the wires of the ohmmeter (3) between
wires A, B and C (2). The resistance between each
of the wires must be low (0.1 W). If the resistance
is greater than this value, it indicates a possible
break in the winding, i.e. an open circuit. A lower
value (0.0. for example) indicates a short circuit in
the winding. If the result of this check is not satisfactory, replace the stator (1) and its casing.
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STATOR -CHECKING THE INSULATION

Z Check the insulation of each winding with respect
to the alternator casing. There must not be any
continuity between the winding and the casing. If
the ohmmeter (2) indicates any value other than an
open circuit, replace the entire stator (1).
CHECKING THE ROTOR

Before checking the rotor components, inspect the
slip rings to make sure that they are in good condition.
Z Check that the slip rings are clean and smooth. If
necessary, clean them with a cloth soaked in gasoline. If the slip rings are burnt, scrape them with
very fine sandpaper (do not use emery cloth) and
wipe them.
NOTE: make sure that the sandpaper is sufficiently
fine in order to obtain a perfect finish of the slip ring
surfaces and avoid premature wear of the brushes.
Z If the slip rings are excessively worn, replace the
rotor.
ROTOR - CHECKING THE CONTINUITY OF THE
FIELD WINDING
Z Connect an ohmmeter (3) between the two slip
rings (2). The resistance must be 2.6 ohms at
20 C.
If the resistance is incorrect, replace the rotor (1).
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ROTOR - CHECKING THE INSULATION OF THE

FIELD WINDING
Z Using an ohmmeter (3), measure the resistance
between each slip ring (2) and the rotor terminals
(1). The resistance should always be infinite. If a resistance is not infinite, replace the rotor.
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6.6
157
FAULT FINDING
PROBLEM
Not recharged
CAUSE
Recharge circuit interrupted
(warning lamp, fuse, connector,
etc.).
CORRECTION
Check the connections of the
recharge circuit, clean and tighten
the alternator and battery terminals.
Replace the part.
Voltage regulator inefficient

Replace the part.
Rotor winding cut out
Replace the part.
Worn brushes
Recharge insufficient
Excessive recharge
Slackened fan belt
Supply the correct voltage.
Voltage regulator faulty
Replace the part.
Excessive wear of rotor rings or

brushes
Replace the part.
Short-circuited diodes
Replace the part.
Stator windings or rotor winding

short-circuited
Replace the part.
Loose circuit connections
Check the connections of battery

terminals, starter motor terminals
and alternator.
Replace the part.
Voltage regulator inefficient

Ground connection faulty
Check connections for leaks.
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BATTERY
For the loader backhoe models two different kinds of installation are provided:
Z with one battery.
Z with two batteries (for cold climates).
7.1
SPECIFICATIONS
Single battery
Voltage: ........................................................................................................................................................12 V
Capacity (20 h):..........................................................................................................................................95 Ah
Discharge current:......................................................................................................................................900 A
Weight with electrolyte: .............................................................................................................................. 25 kg
Double battery
Voltage: ........................................................................................................................................................12 V
Capacity (20 h):..........................................................................................................................................60 Ah
Discharge current:......................................................................................................................................600 A
Weight with electrolyte: .............................................................................................................................. 17 kg
7.2
All models feature one or two 12 volt, negative

ground, maintenance free lead calcium (Pb-Ca)
type battery, of six cell construction.
IMPORTANT: Maintenance Free means that under normal charging conditions the battery does not
lose water from the electrolyte. Conditions that may
cause water loss include prolonged charging above
14.4 volts where gassing occurs as it approaches full
charge. This can be caused by a faulty charging system or boost/recovery charging equipment.
The battery has four major functions:
Z To provide a source of current for starting, lighting
and instrumentation.
Z To help control the voltage in the electrical system.
Z To furnish current when the electrical demands exceed the alternator output.
Z To support quiescent loads from radio and micro
processor memory.
The battery is constructed in such a manner that
each cell contains positive and negative plates
placed alternatively next to each other. Each positive
plate is separated from a negative plate by a non
conducting porous envelope separator. If any of the
positive plates should make contact with negative
plates within a cell, the cell will short circuit and suffer
irreparable damage. All of the positive plates are
welded to a bus-bar, forming a positive terminal and
all of the negative plates are welded to a similar busbar forming a negative terminal.
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Each positive plate is composed of a lead grid with

lead peroxide pasted into the grid openings.
The negative plates are composed of a lead grid with
spongy lead pasted into the grid openings.
The plates are submerged in a liquid electrolyte solution of diluted sulphuric acid.
7.3
BATTERY REPLACEMENT
Use the ignition switch key to open the battery box

and then remove the tool box.
SWARNING
A spark or flame can cause the electrolyte in a battery to explode. To prevent any risk of explosion, observe the following instructions:
Z Place the battery master switch key in the OFF position (disconnected).
Z When disconnecting the battery cables, always disconnect the negative cable (-) first.
Z When reconnecting the battery cables, always connect the negative (-) cable last.
Z Never short-circuit the battery terminals with metal
objects.
Z Do not weld, grind or smoke near a battery.
SWARNING
Batteries produce explosive gases. Keep away any
flame, spark or cigarettes. Always provide good ventilation when charging a battery or using a battery in
an enclosed space. Always protect your eyes when
working near a battery.
SWARNING
Before carrying out any welding on the machine or
repair work on the electrical circuit, disconnect the
battery and disconnect the B+ and D+ wires on the
alternator. When reconnecting, check the wire markings.
SWARNING
Always store batteries in a safe place, out of the
reach of children.
SWARNING
Never touch the battery terminals with your hands.
This can induce a state of electrolysis and impair the
main organs of the body.
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Z Remove the battery master switch support (6) without disconnect the battery cables.
Z Remove the terminal covers and disconnect the
cables, first from the negative terminal (1) then the
positive terminal (2).
Z Remove the nuts and washers (3), the clamping
bar (4) and the brackets (5) and remove the old battery.
Z Install the new battery.
Z Install the brackets (5), the clamping bar (4) and the
washers and nuts (3).
Z Clean the cables and the connecting terminals and
coat them with grease.
Z Connect the cables, first to the positive terminal (2),
then the negative terminal (1) and install the terminal covers.
Z Remove the battery master switch support (6).
SWARNING
Never reverse the battery terminals. Connect the
positive cable to the positive terminal (+) and the
negative cable to the negative terminal (-).
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7.4
161
MAINTENANCE
SPECIFIC GRAVITY
MAINTENANCE
The specific gravity of the battery electrolyte indicates the state of charge.
Fully charged the specific gravity of the electrolyte is
1.280 minimum at 25 C.
Alternatively the approximate state of charge can be
measured by using an accurate digital volt meter (+/
-0.01 V) as follows:
Less than ................. 10.5 V Battery unserviceable*
Less than ....................... 11.8 V Battery discharged
Less than ......................12.3 V Battery 1/2 charged
Better than .................. 12.6 V Battery fully charged
* See note under tests for possible recovery of a
mildly sulphated battery.
Battery voltage to be taken with the battery unloaded and:
A. After the battery has rested unloaded for at least
4 hours.
B. If the vehicle has recently run or battery has recently been charged, switch on headlamps for 2
minutes.
When a battery discharges, sulphuric acid in the
electrolyte combines chemically with the plates and
this action lowers the specific gravity of the solution.
A battery hydrometer will determine the specific
gravity of the electrolyte in a cell and the amount of
unused sulphuric acid in the solution is a measure of
the degree of charge of that cell.
The lower the temperature at which a battery is required to operate, the more necessary it is that the
battery is maintained in a fully charged condition.
For example, a battery with a low specific gravity of
1.225 at 27 C will operate the starting motor at
warm ambient temperatures, but may not be able to
do it at low temperatures due to a lower battery efficiency.
Table shows the effect of temperature on the efficiency of a typical battery.
Temperature
Efficiency of a fully
charged battery
temperature
25.0 C
-4.5 C
-24.0 C
-27.5 C
-31.0 C
-34.5 C
-37.5 C
100%
82%
64%
58%
50%
40%
33%
Maximum battery life will be obtained if the correct

care and periodic inspection is given. It is important
that output capacity should not be exceeded by constant and excessive overloading and that charging
requirements are maintained.
SWARNING
Battery electrolyte causes severe burns. The battery contains sulphuric acid. Avoid any contact with
the skin, eyes or clothing.
Antidote:
EXTERNAL: rinse well with water, removing any
soiled clothing.
INTERNAL: avoid vomiting. Drink water to rinse
your mouth. Consult a doctor.
EYES: rinse abundantly with water for 15 minutes
and consult a doctor.
Battery terminal tightness check ... Every 250 hours
Electrolyte level inspection.......... Every 1000 hours
When servicing a battery the following steps should
be observed:
Z Maintain the electrolyte to the recommended level
of 6 mm above the plates. If this is not observed
the acid will reach a high concentration that will
damage the separators and impair the performance of the plates.
Z Use only distilled or de-mineralized water, do not
overfill and never use tap water or water from a
rain barrel or other source.
Z Always keep the battery at least 75% charged otherwise the plates will become sulphated and loss
of efficiency will result with possible damage from
freezing at low temperatures.
Z Avoid overcharging the battery as excessive
charging will create high internal heat that will
cause plate grid deterioration and produce water
loss.
Z When fast charging ensure the battery temperature does not exceed 50 C.
Z Do not add sulphuric acid to a cell unless the electrolyte has been lost through spilling. Before replenishing ensure the solution is at the correct
specific gravity. A slow charge is the only method
to be employed to fully charge a battery. A high
rate charger can be used to quickly boost the battery capacity but this must be followed by a slow
charge rate to bring the battery to full capacity.
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DRY CHARGED
Z Remove the battery cell vent plugs.
Z Fill each cell to the recommended level with electrolyte of 1.260 specific gravity.
Dry charged batteries must be prepared for service
as follows:
NOTE: the electrolyte must be diluted sulphuric acid
preferably at a temperature of 21 - 32 C.
Z After filling, allow the battery to stand for 15 minutes then re-check the electrolyte level and top up
if necessary.
Z Charge the battery for 4 hours at a rate of 5-8 amperes and check that all cells are gassing freely.
Z Install the battery cell vent plugs.
CHARGING THE BATTERY
Before charging a battery:
Z Thoroughly clean the battery casing and cell covers with dilute ammonia or hot water and clean the
terminals.
Z Check the level of the electrolyte in each cell and,
if below plates, add distilled water to bring above
plate level.
NORMAL (TOP-UP) CHARGING
Z With a slow charger use a rate of 3 to 6 amperes
for the time necessary to bring the battery to full
charge. This may take 36 hours or more if the battery is heavily discharged. A severely sulphated
battery might not accept a charge. When the battery is fully charged the cells will gas freely and the
specific gravity will remain constant. Remove the
charger after three consecutive hydrometer readings taken at hourly intervals indicate that the specific gravity has stopped rising.
Z When using a fast or high rate of charge carefully
follow the manufacturers instructions. High rate
charging raises the temperature of the electrolyte
and unless the charger is equipped with an automatic time or temperature device, the electrolyte
temperature could exceed 50 C, which may cause
violent battery gassing and damage to internal
components.
Z Re-check the level of electrolyte in each cell and
add distilled water as necessary.
SWARNING
When a battery is being charged an explosive gas is
produced. Do not smoke or use an exposed flame
when checking the electrolyte level and ensure the
charger is switched off before connecting or disconnecting to avoid sparks which could ignite the gas.
RECHARGING DEEPLY DISCHARGED
The recommended method to recharge a maintenance free Pb-Ca battery is to use a constant voltage charger. For deeply discharged batteries a 48
hours charging period at 16 volts is recommended,
with current limitation, (47.5 A for 95 Ah).
This system is self regulating: high current is delivered at the beginning (when battery voltage is low),
lower and lower current is then absorbed when battery reaches full charge (and its voltage is high).
If only constant current chargers are available it is
recommended to use the current levels and times.
The figures are intended for deeply discharged batteries. If the battery is only 50% discharged use one
half of the time listed (slow charge programs). For
other states of discharge reduce proportionally the
time of charge. Whenever possible use the slowest
charge program to increase the batterys life.
If when charging the battery, violent gassing or
spewing of electrolyte occurs, or the battery case
feels hot (50 C or greater), reduce or temporarily
halt charging to avoid damaging the battery.
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7.5
163
TESTS
Before commencing battery tests check the battery

for clogged vents, corrosion, raised vent plugs or a
cracked case.
Test equipment required:
Z Hydrometer.
Z Battery starter tester (High rate discharge tester).
Z Thermometer.
Z Battery Charger.
SPECIFIC GRAVITY
This test will determine the state of battery charge.
1. With the float in the vertical position take the
reading.
2. Adjust the hydrometer reading for electrolyte
temperature variations by subtracting 4 points
(0.004 specific gravity) for every 5.5 C below
the temperature at which the hydrometer is calibrated and by adding 4 points (0.004 specific
gravity) for every 5.5 C above this temperature.
The following examples are calculated using a hydrometer calibrated at 30 C.
Example 1:
Temperature below 30 C
Electrolyte temperature...................................19 C
Hydrometer reading ........................................1.270
Subtract (11.0 / 5.5) x 0.004 ...........................0.008
Corrected specific gravity................................1,262
Example 2:
Temperature above 30 C
Electrolyte temperature...................................40 C
Hydrometer reading ........................................1.220
Add (10.0 / 5.5) x 0.004 ..................................0.007
Corrected specific gravity................................1.227
3. Use the following table to determine the state of
charge.
State of
Charge
100%
75%
50%
25%
Discharged
Corrected Corrected
specific
specific
gravity @ gravity @
15 C
25 C
1.295
1.253
1.217
1.177
1.137
1.287
1.246
1.210
1.170
1.130
Average
battery
voltage
2.76
12.52
12.30
12.06
11.84
NOTE: specific gravity should not vary more than

0.025 points between cells.
4. If the specific gravity is 1.280 or more the battery

is fully charged and in good operating condition.
5. Should the corrected specific gravity be below
1.280, charge the battery and inspect the charging system to determine the cause of the low
battery charge.
NOTE: if distilled water has recently been added the
battery should be recharged for a short period otherwise accurate hydrometer readings will not be obtained.
If the battery has been charged under static conditions, denser electrolyte will accumulate at the bottom of the cells. The battery should be shaken
periodically to mix the electrolyte, this will improve
the charge rate and provide a more accurate hydrometer reading when tested.
PERFORMANCE TEST
The performance test is to determine if the battery
has adequate capacity to turn the engine. The voltage reading obtained is used to determine the battery condition. Prior to testing, ensure the electrolyte
level is correct and the open circuit voltage is 12.5 V
or more.
The battery may be tested on or off the loader backhoe.
1. Set the current control switch of the battery
starter tester (high rate discharge tester) to the
off position and the voltage selector switch
equal to, or slightly higher than, the rated battery
voltage. Connect the tester positive leads to the
battery positive terminal and the negative leads
to the negative battery terminal.
2. Turn the current control knob until the ammeter
reading is half the CCA rating of the battery and
take the voltage reading.
Z If the reading is 9.6 volts or more after 15 seconds,
the battery has an acceptable output capacity and
will readily accept a normal charge.
Z If however the reading is below 9.6 volts, the battery is considered unsatisfactory for service and
should be test charged as described below.
SCAUTION
Do not leave the high discharge load on the battery
for periods longer than 15 seconds.
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TEST CHARGING
This test is designed only for batteries that have
failed the previous capacity test.
1. Attach the battery starter (high rate discharge
tester) positive leads to the battery positive terminal and the negative leads to the battery negative terminal.
2. Connect the battery charger positive lead to the
battery positive terminal and the negative lead
to the battery negative terminal.
3. Turn the charger timer past a 3 minutes charge
indication and then back to the 3 minutes
mark.
4. Set the charging rate as close as possible to 40
amperes.
5. After 3 minutes at this fast charge take the voltmeter reading.
Z If the total voltage is over 15.5 volts the battery is
unsatisfactory and is probably sulphated or worn
out and should be replaced.
NOTE: a mildly sulphated battery can be recovered
by using a multiple battery type charger, with an
open circuit upper voltage limit of 50 V.
Owing to the high resistance of a sulphated battery,
it will primarily require a high voltage setting to overcome the resistance of the sulphation initially there
may be no visible acceptance of the charge. After a
few minutes of inactivity a small charge will be apparent, followed by a rapid increase in the charge
rate. The charge rate must not exceed 14.0 amperes or the electrolyte temperature 50 C.
When the ampere rate is stable, reset the volts until
the charge ampere rate is a steady 5 A.
Continue at this rate until the electrolyte specific
gravity stops rising at approximately 1.275 - 1.280 at
20 C, this can take up to 48 hours of charging.
Stand the battery for 24 hours and then conduct the
capacity test detailed previously.
Z If the total voltage is under 15.5 volts, test the specific gravity of each cell and re-charge the battery
to the following scale:
Specific Gravity
Fast charge up to:
1.150 or less
60 minutes
1.151 to 1.175
45 minutes
1.176 to 1.200
30 minutes
1.201 to 1.225
15 minutes
(Slow charge only)
NOTE: when battery problems are experienced the
fan belt tension and the complete charging system
should be checked.
COMMON CAUSES OF BATTERY FAILURES

Z Internal open circuit.
Z Internal short circuit.
Z Loss of electrolyte.
Z Separation of active materials from grids.
Z Accumulation of sulphate crystals too large to disperse.
These failures are normally caused by the following:
Z Failure of inter cell components.
Z Excessive crystal growth may puncture the separators and cause short circuits.
Z Excessive over charging (charging system malfunction, boost/recovery techniques with high voltage, operation in very high temperatures).
Z Freezing of electrolyte. A fully charged battery
does not freeze until -65 C. A 50% charged battery freezes between -17 C and -27 C. Fully
discharged electrolyte freezes at -3 C to -11C.
Excessively high boost charging and gassing will
also cause separation of active materials from
the grids. Separation destroys the chemical
function of the battery.
Z Crystal growth occurs whenever batteries are left
discharged. High temperatures and extended discharged periods increase this condition.
At room temperature after one week the battery is
unlikely to recover on the vehicle.
Recharge will require a higher constant voltage.
After 3 weeks the battery will have suffered permanent degradation and the procedure detailed previously for charging a Deeply Discharged battery
should be followed.
When fully charged, batteries have a long shelf life.
The lead calcium type battery self discharges at 3%
per month. This means that it will take 16 months to
lower to 50% charged. On the loader backhoe the
quiescent load is about 50 mA. To predict rundown
on a static vehicle this should be added as approximately 8 Ah per week.
It is worth stressing that when cranking, if a battery
starts to fade, it is beneficial to stop and allow two
minutes for the battery to recover. The recovery time
should be increased as the temperature decreases.
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7.6
CONNECTING A BOOSTER BATTERY
SWARNING
When the electrolyte of a battery is frozen, it can explode if you attempt to charge the battery or if you try
to start the engine using a booster battery. Always
keep the battery charged to prevent the electrolyte
freezing.
SWARNING
Connecting jumper cables wrongly or short-circuiting
battery terminals can cause an accident. Connect
the jumper cables following the instructions in this
manual.
IMPORTANT: make sure that the voltage of the
booster batteries is the same as that of the machine
circuit (12 V).
Z Open the battery box and then remove the tool box.
Z Remove the terminal covers.
Z Connect the positive (+) jumper cable to the positive (+) terminal of the machines battery.
Z Connect the negative (-) jumper cable to one of the
fastening screws (1) of tank.
Z Start the engine
Z First disconnect the negative (-) jumper cable, then
disconnect the positive (+) jumper cable from the
booster battery.
Z Install the terminal covers.
Z Install the tool box and close the battery box.
7.7
BATTERY MASTER SWITCH
The battery master switch is located into battery

compartment and is used to disconnect the electrical
system completely from the battery.
When the battery master switch has an inclination of
45, the system is disconnected.
When the battery master switch is in horizontal position, the system is connected.
SWARNING
The battery master switch must be switched off at
the end of each working day, for machine service or
for any operations on the electrical system. It acts as
an anti-theft device when the cab doors and windows are locked.
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8.
COMPONENT TESTING
8.1
GENERAL INTRODUCTION
No special tools are required to remove or replace

electrical components.
Refer to the appropriate section of this Service Manual
for overhaul procedures regarding the starter motor
and the alternator.
Fault finding of electrical systems should be carried out
in a logical and methodical fashion. A few minutes
spent understanding the system and analysing the
symptoms can save considerable time.
An essential piece of equipment for checking electrical
systems is a good quality multimeter with a high impedance which can measure voltage, current and resistance.
NOTE: labelling of connectors prior to disassembly will
greatly assist when reconnecting any harness.
Where it is necessary to clean the multiple connectors,
a contact spray should be used.
IMPORTANT: DO NOT use a cleaner that contains
trichloroethylene which will dissolve the plastic connectors.
The wiring harnesses contain wires which are colour
coded for identification.
Each harness can be removed and replaced, but certain precautions must be observed:
Z Disconnect or isolate the battery, negative terminal
first, prior to disconnection or removal of any wiring
harness.
Z Prior to removal, note the harness routing, clamping
positions and terminal connections.
Z On replacement, be sure that the harness routing is
not in contact with sharp edges, the exhaust system
or moving parts.
Z Check connections for wire colour matching.
Z Use a light coating of di-electrical grease on the connector pins to prevent corrosion.
Z Be sure that all connectors are fully engaged and no
conductor is exposed.
Z Tape back unused connectors.
Z Be sure that ground connections are clean with metal-to-metal contact. Use toothed lock washers for
good ground connections.
Z Be sure that fuses are of the specified rating.
Z Check the system amperage before applying power
to the wiring.
Z Check polarity of the battery before connecting power to the harness.
Z When it is necessary to remove or partially disconnect a wiring harness, label each connector before
removal from its mating instrument.
F28375
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8.2
167
COMPONENT TESTING
In general with the key start on there should be 12 V

found at the component connections.
Where 12 V is not present check fuses, relays and
wiring for breaks.
8.3
GROUND POINTS
NOTE: always ensure the ground points are clean

and functional. A poor ground will cause the electrics
to fail.
Ground point A - Starter motor (engine harness)
Ground point A is also linked to ground point B.
Ground point B - Right hand console (front console harness)

This is also linked to ground points A, C, and D.
F32641
Ground point C - Rear of chassis (Chassis harness)

This is also linked to ground point E.
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Ground point D - Fuse board

This is also a back-up ground point for Location E.
XC5
F5/B
F5/A
K5
K6
F6/C F7/C F8/C
K7
F6/B F7/B F8/B
K8
F6/A F7/A F8/A
K9
15v
GND
30v
D
F28379
Ground point E - Top right hand B pillar (roof

harness)
F28380
Ground point F - Operatorseat light
F
F28381
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8.4
STARTER SWITCH KEY AND STOP

SWITCH
NOTE: when the starter switch key/stop switch is

turned to ON, the audible alarm sounds until the engine is started or the key is returned to the initial position.
Starter switch key
1. Not used
2. Off
3. Ignition ON
4. Cranking
CONTACTS
MAXIMUM
CURRENT
12 V
MAXIMUM
CURRENT
24 V
TIME
30-58
8A
4A
30-15/54
35 A
17.5A
30-50a
70 A
18 A
40 A
5A
1 min
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ALTERNATOR
This sends a square wave signal, the frequency of

which varies between 142.52 855 Hz (480 - 3060
rpm) to the instrument panel.
With the engine running, the warning light should
turn off. If not, disconnect the wire connected to the
terminal D+ (pink wire).
When D+ is not connected and the warning light
goes out, there is a fault with the alternator. If it does
not turn off, then check the bulb and the wiring loom.
F28388
8.6
TRANSMISSIONS
POWERSHUTTLE DISCONNECT - X23/X28

Energizes the transmission dump solenoid at 12 V.
F28392
Test procedure
Continuity should be found between pin 1 and pin 2
when switch is operated.
X23
2: RM:A-R:1
1: RM:B-R:1
X28
2: RM:A-R:1
1: RM:B-R:1
4: RM:C-N:1
3: RM:N:1
F28391
POWERSHIFT EGS CONNECTOR

The EGS receives input from the FWD Switch,
brakes, switches, transmission disconnect switch,
temperature sensor and speed sensor. The EGS
also sends signals to the transmission control valve.
For input and output tests to check correct operation
of the EGS, refer to Section 21.
Test Procedure
Test procedure of the speed sensor refer to the next
page.
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POWERSHIFT CONTROL UNIT

The control unit receives the signals switching ON or
OFF the solenoids and allowing the desired gears to
be selected. A variable current solenoid receives a
reducing signal from the EGS controlling modulator.
The control unit is equipped with a combined temperature and speed sensor which sends signals
back to the EGS.
Test Procedure
Test between pin indicated in the left hand column
and either pin H or M as detailed in the table below.
F28394
DESCRIPTION
Pin
No.
27.5
27.5
27.5
27.5
27.5
27.5
14
31
*A
B
C
D
E
F
G
K
L
M
Speed sensor plus output 24

Forward Lo/Hi solenoid
Forward/neutral solenoid
Range 1/2 solenoid
FWD solenoid
Reverse neutral solenoid
Direction modulation solenoid
Transmission temperature out ground
Control valve common plus
F28395
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POWERSHIFT SPEED SENSOR TEST

Disconnect from control valve and fit the 12 pin connector from special tool.
Connect the power socket to the 12 V socket.
Install the probes from a multimeter into the tool.
Raise the unit off the ground and observe voltage
(V1). Turn the rear wheel which in turn rotates the
transmission output shaft, observe the second voltage (V2).
F28394
Test procedure
Pin
No.
V1
V2
0.6 - 0.8
1.3 - 1.5
The special tool connects to pin A speed sensor plus

output, and pin J speed sensor/temperature sensor
ground.
F28397
Description
A Speed sensor +
B FWD request
C Disconnect request input
D Speedometer output
E Diagnostics link input
F Analogue Input 1
G Analogue Input 0
H J K PWM solenoid supply
L Solenoid 3
M PWM 1
N Range solenoid 27
P Forward solenoid
R Solenoid 2
S Solenoid 1
T VCS
U Ground
V Battery +
B
C
D
E
P
R
F
A
N
V
S
G
M
U
T
L
K
J
F28398
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POWERSHIFT EGS OVERRIDE

In situations where a MANUAL gearshift (up or
downshift) is required, the powershift transmission
auto change can be overridden by selection of this
console-mounted switch.
Test procedure
Continuity should be found between pin 1 and pin 2
when switch is operated.
7: Z/N1
5: N1
F28400
OIL PRESSURE SWITCH - POWERSHIFT

Energized at 12 V if the transmission pressure is to
low, the warning lamp will flash.
F28402
Test procedure
The voltage measured between pin 1 and pin 2
should be 12 V.
With Transmission oil pressure continuity should be
found.
Pin
No.
Sender
Resistance
12 V
with low pressure 0.3
Z-B:1
N:1
F28403
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OIL PRESSURE SWITCH - POWERSHUTTLE

If the transmission pressure is to low, the warning
lamp to flash.
F28404
Test procedure
The voltage measured between pin 1 and pin 2
should be 12 V.
With Transmission oil pressure continuity should be
found.
Pin
No.
Sender
Resistance
12 V
with low pressure 0.3
Z-B:1
N:1
F28403
8.7
PARKING BRAKE SWITCH
When the parking brake is engaged, the switch is

deactivated and the warning lamp turns on.
An audible alarm sounds if the parking brake is operated with the gearshift lever engaged.
Test procedure
Brake engaged:
switch closed warning light illuminated.
Brake disengaged:
switch open warning light off.
S18
1: FM:G-R:1
1: FM:N:1
F28407
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8.8
175
CAB
FRONT INSTRUMENT
The front instrument cluster receives signals from
the brake oil level sender, the transmission speed
sensor, the light switch and the indicator switch.
Behind the instrument there are connectors attached to the vehicle wiring.
These connectors and functions are listed on the following pages.

Receives signal from sensors to display, hours, engine RPM, oil pressure, fuel level and signals to
warning and indicator lights.
FRONT INSTRUMENT CLUSTER CONNECTOR AMPERE 070 12-WAY POWERSHUTTLE

Pin functions and test procedure
Listed below are the pin numbers, warning lights,
and gauges.
1. Starter switch key 12 V
2. Ground:
check continuity
3. Tachometer:
Signal from W output of the alternator
4. Dipped beam:
green warning light illuminates at 12 V with multi
function light switch on
5. Main beams - Blue warning light illuminates at
12 V with multi function switch on
6. 12 V and instrument backlighting
7. Not used
8. Not used
9. Not used
10. Not used
11. Direction indicators:
green warning light illuminates at 12 V with light
switch on
12. Brake oil level:
red warning light when the input is connected to
ground with Ignition on 12 V
12
6
F28412
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Copyright

Calibrations
GAGE TYPE
INPUT
FUEL LEVEL
320 OHMS
+0/-2
185 OHMS
3 (Ref)
6.5 OHMS
+4/-0
208 OHMS
ON
5 OHMS
200 OHMS
OFF
5 OHMS
50 RPM
LOW FUEL LAMP
READING
TOLERANCE
TACHOMETER
Can message
0-3000 RPM
COOLANT
TEMPERATURE
Can message
Minimum reading (65 C)
3 C
Can message
Left edge of red band (106 C)
2 C
Can message
Maximum reading (112 C)
3 C
11 V
3 C
16 V
Left edge of upper red band
3 C
358 OHMS
Minimum reading (75 C)
3 C
149 OHMS
Left edge of red band (105 C)
2 C
112 OHMS
Maximum reading (115 C)
3 C
VOLT
TRANSMISSION
TEMPERATURE
Connectors
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CN1
PIN
FUNCTION
NOTE
Not used
Key on power
Wake up
In gear input
Digital input
Driving lights
Digital input
Front work lights
Digital input
Rear work lights
Digital input
Turn signals
Digital input
Main beams
Digital input
Brake fluid level low
Digital input
10
Air conditioning system pressure
Digital input
11
Digital input
12
Enter input switch
Digital input
13
Up input switch
Digital input
14
Down input switch
Digital input
15
Cranking
Digital input
16
Digital input
17
Not used
18
Parking brake
19
Not used
20
Digital input
21
Decelerator button
Digital input
22
Crab steering
Digital input
23
Road steering
Digital input
24
Turn steering
Digital input
25
Transmission oil pressure
Digital input
26
Not used
Digital input
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178
CN2
PIN
FUNCTION
NOTE
Keep alive power
Need to fuse at 1 ampere without disconnect
Not used
Can bus input
Twisted pair, with 120 OHM terminator
Can bus input
Twisted pair, with 120 OHM terminator
Not used
Floyd bell under 80 mA
40 OHM relay = 300 mA
Not used
Not used
10
Not used
11
Not used
12
Not used
13
Fuel level gauge
Variable resistance
14
Transmission temperature
Thermistor
15
Not used
16
Foot accelerator
0.5 - 4.5 V
17
Accelerator knob
0.5 - 4.5 V
18
Foot accelerator
Output monitored for diagnostics
19
Accelerator knob
Output monitored for diagnostics
20
Foot accelerator
21
Accelerator knob
22
Not used
23
Not used
24
25
Not used
26
Ground
Low alternator output signals fault

Digital input
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FRONT INSTRUMENT CLUSTER CONNECTOR AMPERE 070 12-WAY POWERSHIFT

Pin functions and test procedure
Listed below are the pin numbers, warning lights,
and gauges.
1. Starter switch key 12 V
2. Ground:
check continuity
3. Tachometer:
signal from W output of the alternator
4. Dipped beam:
green warning light illuminates at 12 V with multi
function light switch on
5. Main beams - Blue warning light illuminates at
12 V with multi function switch on
6. 12 V and instrument backlighting
7. Not used
8. 4WS - Green warning light four wheel input. With
Ignition ON and 4WS selected 0.5 V should be
indicated.
With 2WS or crab steer selected, 0 V should be
indicated.
9. Crab steer - Green warning light
10. 2WS - Green warning light 2WS input. With Ignition ON and 2WS selected 1.5 V should be indicated.
With 4WS or crab steer selected, 12 V should be
indicated.
11. Direction indicators:
green warning light illuminates at 12 V with light
switch on
12. Brake oil level:
red warning light when the input is connected to
ground with ignition on 12 V
12
6
F28412
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8.9

4WD SWITCH
Test procedure
Continuity
Switch OFF
Position 1
Position 2
From pin 7
to pin 5
From pin 5
to pin 3
From pin 1
to pin 3
From pin 6
to pin 8
From pin 4
to pin 6
From pin 2
to pin 4
Voltage:
Ignition ON:
Pin 3 = 12 V
Pin 6 = 9 V
F28417
8.10 BRAKE PEDAL SWITCHES

Test Procedure
Continuity:
Brakes not applied: no continuity.
Brakes applied: continuity, between the two centre
pins of each switch.
Both brake pedals must be applied to allow 12 V to
relay.
F28419
Voltage:
Left switch:
White / red wire
Red wire
Right switch:
Red wire
Red - Black wire
12 V continuous with ignition

ON
12 V pedal depressed
0 V pedal released
0 V pedal released
0 V pedal released
1: R:1
1: R:1
2: R-N:1
2: B/R:1
F28420
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8.11 BRAKE OIL LEVEL WARNING LAMP

When the warning lamp is turned on due to a low oil
level, it sends a signal to the instrument cluster to illuminate the relevant warning lamp.
Test procedure:
Continuity:
With the fluid level correct there should be no continuity through the switch. Continuity should be seen
when the level is low or the test button pushed.
Voltage:
With the Ignition ON there should be 12 V at the
Red/Black terminal.
1: G-R:1
2: R/N:1
F28422
8.12 FRONT WORK LAMP SWITCH (1) REAR WORK LAMP SWITCH (2) MAIN
LIGHT SWITCH
There must be 12 V at the switch only after the main
light switch and the starter switch key have been activated.
Test procedure
(Switch Off)
Continuity should not be found between any pins.
(Switch On)
Continuity should be found between pins 1 and 3
and 2 and 8.
F28417
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8.13 HAZARD SWITCH

12 V should be found at this switch at all times regardless of key start position.
Test procedure
Pin No.
Switch OFF
Switch ON
to pin 4
to pins 5/6/7
to pin 1
1: S-N
3: A-G
to pins 2/3/6/7
7: A/V
4: H-R
6: L/B
5: L/R
to pins 2/3/5/7
to pins 2/3/5
F28428
8.14 HAZARD WARNING LIGHT RELAY

Operational at all times in conjunction with the hazard switch.
K12
K10
XC1 XC2
F1/C F2/C
Continuity
Pin
No.
Hazard / Indicator
Switch OFF
Switch ON
CL
12 V
12 V
12 V - 0 V - 12 V - 0 V
31
12 V - 0 V - 12 V - 0 V
PR
F28431
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8.15 MULTI FUNCTION SWITCH

Switch Continuity
Pin
All
WindNo. switches shield
OFF
washer
1
2
3
4
5
6
7
8
9
Indicator
Left
Right
Beam
Low
High
Wiper
seal
On
pin 7
pin 4
pin 5 pin 3
pin 4
pin 8
pin 2
pin 8
pin 7
pin 6
pin
11
10
11
pin 9
2: L-B:1
4: G/R:1
5: V/N:1.5
6: A/B:1
7: A/N:1
8: A/R:1
9: L:1
10: A-V:1
11: L-N:1
pin
11
pin
10
12
12
7
6
F28433
8.16 FRONT WINDSHIELD WIPER MOTOR

(1) - REAR WINDSHIELD WIPER
MOTOR (2)
Energized at key start at 12 V.
F32628
Test procedure
Pin No.
Continuity
Continuity
pin 3
pin 5 2
pin 5 2
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8.17 4WS - STEERING SELECTOR SWITCH

At key start 12 V should be found at the switch and
is directed to the steering sensors when a switch selection is made.
Test procedure
With ignition ON
Pin
2WS
4WS
CRAB
12 V
12 V
12 V
12 V
12 V
C
B
V/N
L-R
C-G
F28438
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8.18 STEERING CONTROL UNIT

The steering control unit controls the different steering functions that can be selected from the switch
S47.
When changing steering mode, the light for the current mode is extinguished and the light for the new
mode starts to flash. When movement of the steering wheel is detected, the light for the new mode remains steady.
Connector pin out description

12 pin connector -X95:
Pin
Function
Signal
Crab steering warning light
Buzzer configuration
Front alignment sensor input
+12
Crab steering control
+12
Buzzer output
Rod iron steering control
+12
Control unit supply
+12
Ground
Speed sensor input
10
Rear alignment sensor input
11
2WS warning light
12
4WS warning light
1: CM:Z/B:1.5
2: CM:C:1
3: CM:H-L:1.5
4: CM:A-R:1
5: CM:V-B:1
6: CM:V/N:1
7: CM:R-G:1
8: CM:N:1
9: CM:A-B:1
10: CM:L/N:1
11: CM:M:1
12: CM:V/B:1
X95
12
7
6
F28441
+12
8 pin connector -X96:

Pin
Function
Signal
EV2A output
+12
EV2B output
+12
EV3A output
+12
Ground
Front sensor supply output
+12
Rear sensor supply output
+12
Available optional output
+12
EV3B output
+12
X96
1: CM:L/R:1
2: CM:S/N:1
3: CM:H/N:1
4: CM:L-N:1
5: CM:A/V:1
6: CM:R/N:1
7:
8: CM:M/B:1
8
1
5
4
F28442
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Solenoid valve operation

Crab/4WS > 2WS
When the rear axle sensor detects alignment of its
axis, the control unit de-energizes the active steering solenoid valves and activates the solenoid
valves for 2WS.
2WS > Crab/4WS
When the rear axle sensor detects bridge alignment, all the solenoid valves for 2WS are de-activated and the solenoid valves for the selected mode
are energized.
Crab > 4WS and 4WS > Crab
When the rear axle sensor detects alignment the
2WS temporarily activates (energizing the corresponding solenoid valves) until, after overcoming
the condition of rear bridge alignment, the desired
steering type activates when, by reversing the steering swing direction, the rear axle sensor detects
alignment.
Solenoid valve failure
The operation condition of any solenoid valve output
is tested each time the selected steering requires its
supply. Even when only one solenoid valve output is
short circuited or open, the control unit provides to
cut the supply to all the solenoid valves by means of
the self protection (the control unit is locked) and to
signal this condition (short - or open - circuit) by
means of the three warning lights relative to steering
flashing at the same time. Once the solenoid valve
causing the failure has been de-energized or the
correct operation has been reset.
Buzzer operation
Buzzer operation depends on setting of pin 2 of the
12 way connector:
Z Pin 2 not connected (North America only). If 12 km/
h is exceeded in crab mode, the buzzer sounds.
Z Pin 2 grounded (Outside of N/America). If 12 km/h
is exceeded in crab or 4WS mode, the buzzer
sounds.
Buzzer operation is intermittent, 250 ms on and 250
ms off.
The control unit is set at 9 km/h; steering mode
change is not possible when this speed is exceeded.
Solenoid valve output
Solenoid
2WS
4WS
EVA2
CRAB
X
EVA3
EVB2
EVB3
Speed pulses
Speed pulses are drawn from EGS-CLARK control
unit. Output reference values of clark transmission
are:
Z 7 Hz for 1 km
Z 14 Hz for 2 km
Z 35 Hz for 5 km
values in V -8 and +8.
The speed calculation has been determined with a
tyre having a circumference of 4.165 m.
Steering type storage
The steering type is stored in a non-volatile memory
each time the machine is turned off. This information
is therefore stored for an indefinite time even with
the supply cut off.
Start-up and axle recovery
The control units are supplied with a storage of the
last steering selected at two wheels. With this steering type selected, it is always possible to recover the
axle alignment; short-circuit the sensor or front and
rear axles, supply the machine (with the switch in 2
wheel position) and select the type of 4WS enabling
the bridge alignment.
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8.19 4WS REAR AXLE STEERING SENSOR

is directed to the steering sensor when the switch
selection is made.
F28443
X98
Pin
2WS
4WS
CRAB
12 V
12 V
12 V
X98
A: RM:L/N:1
B: RM:N:1
C: RM:R/N:1
F28444
8.20 4WS FRONT AXLE STEERING

SENSOR
is directed to the steering sensor when a switch selection is made.
F28445
X97
Pin
2WS
4WS
CRAB
12 V
12 V
12 V
X97
A: RM:H-L:1
B: RM:N:1
C: RM:A/V:1
F28446
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8.21 STEERING SOLENOID VALVE

Energized at 12 V but governed by the steering processor.
F28447
Solenoid valve connections, viewed from the top. Arrow denotes front of loader backhoe.
Solenoid
2WS
4WS
CRAB
EVA2
0V
0V
12 V
EVA3
0V
12 V
12 V
EVB2
12 V
12 V
0V
EVB3
12 V
0V
0V
Pin No.
Solenoid
Resistance
0V
5.0
EVA2 - X91
EVB2 - X92
EVA3 - X93
EVB3 - X94
F28448
X91
X92
1: RM:L/R:1
2: RM:N:1
1: RM:S/N:1
2: RM:N:1
F28449
Pin No.
Solenoid
Resistance
0V
5,0
X93
X94
1: RM:H/N:1
2: RM:N:1
1: RM:M/B:1
2: RM:N:1
F28450
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8.22 DIFFERENTIAL LOCK SWITCH (1)

At key start the spring loaded switch has 12 V and
when operated energizes the differential solenoid
valve.
Test procedure
(Switch Off)
Continuity should not be found between any pins
(Switch On).
Continuity shoud be found between pins 1 and 5.
1: M/B1
5: C-B1
F28452
Pin No.
Solenoid
Resistance
0V
5.0
X8
1: RM:CL:1
2: RM:N:1
F28453
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8.23 LOADER
GLIDE RIDE (1)
Designed to reduce loader attachment oscillations
when travelling with empty bucket.
SWARNING
If the machine is raised using the loader bucket do
not operate the glide switch ensure it is switched
OFF.
Test procedure
(Switch Off)
(Switch On)
1: C/N1
5: A-N1
F28456
EV11
Pin No.
Solenoid
Resistance
EV11
0V
5.0
X34
1: RM:A-N:1
2: RM:N:1
F28457
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LOADER ATTACHMENT LOCK (1)

The loader attachment lock, when actuated, is designed to prevent movement of the loader attachment during road travel.
Continuity should be found between pin 1 and 3.
F28417
Pin No.
Solenoid
Resistance
0V
5.0
1: RM:N:1
2: RM:C-L:1
F28461
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HYDRAULIC SPEED CONTROL (1)

It enables an increase of the moving speed of the
loader attachment.
Test procedure
(Switch Off)
(Switch On)
1: C/N1
5: L-G1
F28464
Pin No.
Solenoid
Resistance
0V
5.0
1: RM:N:1
2: RM:C-L:1
F28461
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8.24 BACKHOE
BACKHOE ATTACHMENT TRAVEL LOCK
SWITCH
At start-up, the switch must have 12 V to disengage
/ engage the backhoe attachment travel lock cylinders.
Test procedure
(Switch Off)
Continuity should not be found between any pins
(Switch On).
1: C/B1
5: B-N1
F28468
Pin No.
Solenoid
Resistance
12 V
9.7
1: RM:A-N:1
2: RM:N:1
1: RM:N:1
2: RM:C-L:1
F28469
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BACKHOE ATTACHMENT LOCK SWITCH (1)

At start-up, the switch must have 12 V for the
operation of the backhoe attachment lock.
Test procedure
(Switch Off) - X25
(Switch On)
1: C-B1
7: L/G1
5: C/B1
F28472
EV5
Pin No.
Solenoid
Resistance
12 V
7.5
1: R-V:1
2: N:1
F28473
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HYDRAULIC HAMMER CONTROL PEDAL

At start-up, the pedal must have 12 V for the operation of the hammer.
When the switch is operated, there must be 12 V at

pin 2.
2: R-V
1: R-V:1
F28476
Pin No.
Solenoid
Resistance
12 V
7.5
1: R-V:1
2: N:1
F28473
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HAND HAMMER SWITCH (1)

At start-up, the switch must have 12 V for the operation of the hand hammer.

pin 1.
1: C-B1
5: C/B1
F28479
Pin No.
Solenoid
Resistance
12 V
7.5
1: H-N
2: N:1
F28480
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ATTACHMENT SWITCH (1)

At start-up, the switch must have 12 V.

pin 5.
1: C/N1
5: V1
F28483
REVERSING BUZZER
Activated by 12 V at key start when reverse gear is
selected.
F28487
F28485
With reverse travel selected, there must be 12 V at

pin connector.
Resistance of the buzzer 162 .
M/B
N
F28488
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FUEL LEVEL GAUGE

The gauge indicating the fuel level is located in the
side instrument cluster.
F28489
Test procedure
Approximate resistance:
Gauge indication
Sensor resistance
Full
Half
129
Empty
333
2: N
1: Z:1
F28490
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580SR
580SR+
590SR
695SR
SECTION 82 - LOADER
1. LOADER ATTACHMENT CONTROLS......................................................................................................... 3
1.1 LOADER ATTACHMENT OPERATION ................................................................................................ 3
2. LOADER BUCKET SELF LEVELING ........................................................................................................... 6
3. LOADER ATTACHMENT SAFETY STRUT.................................................................................................. 7
4. LOADER BUCKET REMOVAL ..................................................................................................................... 8
5. LOADER REMOVAL................................................................................................................................... 11
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SECTION 82 - LOADER
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SECTION 82 - LOADER
1.
LOADER ATTACHMENT CONTROLS
WITH STANDARD LOADER BUCKET

Located on the right of the steering wheel, this nine
position lever operates all the loader attachment
controls. The speed of movement of each control depends on the angle to which the lever is tilted. In the
intermediate position, two movements can be obtained simultaneously.
WITH 4x1 LOADER BUCKET
The function of the lever is identical to that of the machine fitted with the standard loader bucket, with the
addition of the clam control.
1.1
LOADER ATTACHMENT OPERATION
NEUTRAL AND HOLD

With the lever in the neutral/hold position (0), the attachment movement can be stopped. As soon as the
lever is released, it automatically returns to the neutral position (0) and the attachment remains in the
position where it was when movement stopped.
RAISING THE LOADER ATTACHMENT
With the lever in position (1), the attachment rises.
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SECTION 82 - LOADER
LOWERING THE LOADER ATTACHMENT

With the lever in position (2), the attachment lowers.
3
LOADER BUCKET FLOAT CONTROL
With the lever in position (3), the bucket follows the
contours of the ground without it being necessary to
operate the lever.
NOTE: in this position the lever does not automatically return to neutral when it is released. It is necessary to move it manually.
4
FILLING THE LOADER BUCKET
With the lever in position (4), the bucket rolls back
(fills).
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SECTION 82 - LOADER
DUMPING THE LOADER BUCKET

With the lever in position (5), the bucket rolls forward
(dumps).
6
AUTOMATIC RETURN TO LOADER BUCKET
FILLING
With the lever in position (6), the attachment lowers
and, simultaneously, the bucket places itself to the
digging position.
NOTE: it is possible to adjust the tilt angle for bucket
filling.
1.2 4x1 LOADER BUCKET CLAM

CONTROL (If fitted)
This control operates the opening and closing of the
4x1 loader bucket clam.
This control is proportional:
When releasing the roller (7), it automatically returns
to the initial position (neutral) and the bucket remains
in the position where it was when movement
stopped.
It is possible to lock the roller into detent by moving
the roller to the full forward (raised) position. To release the detent, press on the lower portion of the
roller as your return it to the neutral position.
When shifting the roller (7) forward: the loader bucket clam closes (A).
When shifting the control (7) backward: the loader
bucket clam opens (B).
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Copyright
SECTION 82 - LOADER
LOADER BUCKET SELF LEVELING
The self-levelling linkage mounted on the right hand

loader arm and chassis automatically controls the
angle of the loader bucket during the raising cycle of
the lift arms to maintain a constant bucket level.
There is no self-levelling during lowering.
Return to dig is an electrically activated feature
which enables the operator to automatically return
the bucket to a level digging position for a further
work cycle with one simple movement of the loader
control lever (3).
Whenever the bucket is rolled forward to dump, the return to dig system is activated, and the solenoid valve
on the bucket spool is energized.
When the loader bucket control lever (3) is moved diagonally left to the return to dig position (2) the electromagnet will hold the bucket spool in the roll back
position until the bucket is in the level digging position at which time the indicator on the rod of the bucket self-levelling linkage will pass in front of the sensor
which de-energises the electromagnet on the bucket
spool enabling the spool to return to the neutral position.
RETURN TO DIG SENSOR ADJUSTMENT

The return to dig system consists of an electromagnet mounted on the loader bucket control valve
spool, a sensor (1) mounted on top of the loader arm
and a pointer attached to the tube of the bucket selflevelling linkage.
Z Place the bucket on the ground in the preferred digging position.
Z Check the dimensions of 88.5 mm and 7.5 mm are
maintained as shown.
Z Ensure the face of the sensor (1) is 6 mm from rod
(2).
As a visual aid for the operator, while seated in the
cab, the pointer mounted on the loader arm can be
seen to align with the pointer on return to dig linkage,
when the loader arms are lowered and the bucket is
in the level digging position.
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SECTION 82 - LOADER
3.
LOADER ATTACHMENT SAFETY STRUT
Located on the left-hand side of the loader attachment, this safety strut enables the loader attachment to be locked in the raised position in case of
defects in the system.
LOCKED POSITION
Completely raise the loader attachment. Stop the
engine and remove the starter switch key.
Remove the split pins (1) and the safety strut (2)
from the arm. Put the split pins back in place.
Place the strut (2) on the cylinder rod and fasten it
by means of the fastening flip (3).
UNLOCKED POSITION
Remove the flip (3) and the strut (2) from the cylinder rod.
10
Install the safety strut (2) on the loader arm by
means of the split pins (1).
Start the engine and lower the loader attachment.
11
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4.
Copyright
SECTION 82 - LOADER
LOADER BUCKET REMOVAL
REMOVAL
Park the machine on flat surface.
Lower the bucket to the ground in dump position (tilted completely forward).
Stop the engine and remove the starter switch key.
If the machine is fitted with a 4x1 bucket, release the
pressure from the bucket system.
Remove the snap rings and retaining pins and then
drive out the linkage pins (1).
(4x1 bucket) disconnect and plug the hydraulic supply lines.
Start the engine
Operate the attachment controls so as to release the
bucket.
Reverse the machine from the bucket.
INSTALLATION
Make sure all bushings are completely clean.
Remove any dirt or foreign matter, if necessary.
Start the engine
Use the attachment controls to engage the attachment between the bucket lugs.
Install the arm/bucket linkage pins (1) and then install the retaining pins and snap rings.
Use the bucket controls to align the connecting rod
holes with the bucket lugs.
(4x1 bucket) release the pressure from the bucket
system.
Install the connecting rod/bucket linkage pins (1) and
then install the retaining pins and snap rings.
(4x1 bucket) remove the plugs and reconnect the hydraulic supply lines.
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SECTION 82 - LOADER
4.1 LOADER BUCKET WITH FORKS

(Optional)
S WARNING S
The forks are heavy, so use great care when swinging them into their working and stowage position.
INSTALL FORKS IN WORKING POSITION
Move the bucket to a level and firm ground. Stop the
engine and remove the starter switch key. Raise the
parking brake lever.
Remove the retained pin and the pin (1).
Lower the fork (2) manually and carefully until it is
laying in position against the bucket cutting edge.
IMPORTANT: the forks must be laying against the
cutting edge of the bucket, and never against bucket
teeth.
12
Install the pin (1) and the safety pin.
Repeat the same operations for the other fork.
Slide the forks until they are suitably spaced for the
intended job.
IMPORTANT: the two forks must be positioned at
the same distance from the centre of the bucket.
IMPORTANT: never use the forks to lift the machine.
S WARNING S
When using the forks with a 4x1 bucket, never attempt to use the bucket jaw opening function.
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SECTION 82 - LOADER
INSTALL THE FORKS IN REST POSITION

Rest the loader bucket on a level and firm ground.
Disengage the parking brake lever.
Remove the retained pin and the pin (1).
Tilt the fork (2) manually and carefully until it is rearwards into transport position.
14
Reinstall the pin (1) and the safety pin into their housing.
NOTE: if necessary, slide the fork to the side to bring
it into its housing.
Repeat the same operations for the other fork.
IMPORTANT: the forks must be securely retained in
their proper storage position using the pins and split
pins provided for this purpose. If forks are not correctly secured, they can cause serious injury.
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4.2
REPLACING LOADER BUCKET TEETH
Move the machine to a level and firm ground.

Position the loader bucket so that the bucket teeth
can be replaced.
Place the direction-of-travel lever and gearshift lever
in neutral position.
Immobilize the machine by means of the parking
brake.
Loosen and remove the screws (2) with the nuts (3).
Extract the tooth (1).
Clean the area around the tooth.
Assemble the new tooth (1).
Screw in and tighten the screws (2) with the nuts (3).
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SECTION 82 - LOADER
5.
LOADER REMOVAL
Remove the loader bucket (see procedure described

previously).
Fully retract bucket cylinders and raise arm until lift
cylinder pivots can be seen above engine guard.
Place a suitable stand under the end of the arm to
take the weight.
Switch off the engine and relieve hydraulic pressure.
Remove the safety rings (2) and the pins and then
drive out the pins (1). Lower the lift cylinders carefully
onto the chassis.
Remove the snap rings (3) and drive out the pins (4).
Lower the arms onto the lift cylinders.
Disconnect and cap the lift cylinder hoses (5) at the

top of the loader arm on each side of the machine
and disconnect the return to dig sensor cable (7) on
the right hand side. If the 4x1 bucket is fitted disconnect and cap hose (6) on each side of the loader.
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SECTION 82 - LOADER
Support loader using a suitable sling.
Remove the safety ring and pins and then pull out the
pin (8).
Remove the loader from the machine.
INSTALLATION
Installation is removal procedure in reverse.
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580SR
580SR+
590SR
695SR
2. BACKHOE ATTACHMENT MECHANICAL CONTROLS VERSION ............................................................ 6
3. BACKHOE ATTACHMENT HYDRAULIC CONTROLS .............................................................................. 15
4. REMOVAL AND INSTALLATION ............................................................................................................... 17
4.1 CENTER PIVOT BACKHOE ATTACHMENT DISASSEMBLY............................................................ 17
4.2 BACKHOE ATTACHMENT DISASSEMBLY - SIDESHIFT ................................................................. 20
4.3 BACKHOE BUCKET REMOVAL ......................................................................................................... 23
4.4 BUCKET TEETH REPLACEMENT...................................................................................................... 23
4.5 DIPPER REMOVE ............................................................................................................................... 24
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1.
Loader backhoes are available with center pivot or

sideshift backhoe attachment.
On center pivot machines the backhoe pivots on a
fixed central point at the rear of the machine.
Independently operated stabilizers are attached to
the base of the chassis and pivot about an arc to
raise or lower each side of the machine.
On sideshift machines the backhoe is attached to a

carriage hydraulically clamped to the machine frame.
This allows the operator to reposition the carriage on
the frame and to adjust the position of the backhoe
attachment to suit the operating conditions.
The machine is raised using two vertical stabilisers
attached to each side of the machine.
Each stabilizer is independently operated using:

Z levers (1) and (2) on loader backhoe control models mechanical;
Z control levers (3) and (4) on loader backhoe pilot

control models.
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The backhoe attachment is locked in position during

transport using a hydraulically and mechanically operated lock (5).
The lock is operated by the lever (6) or the switch (7).
The backhoe on the mechanical control models is

controlled using two main control levers.
Three types of control pattern for two levers (8) and
(9) systems are available as shown on the following
pages. A four levers dealer installed system is also
available as a Dealer installed accessory.
The backhoe on the hydraulic control models is controlled using two rear hydraulic control levers (10)
and (11).
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Machines may be fitted with an optional telescopic

dipper which can be operated simultaneously with
other boom, dipper and bucket movements.
The telescopic dipper on the manually controlled

models is controlled by a pedal (12) located in the
rear part of the cab.
The telescopic dipper on pilot control modes, is controlled using the two buttons (13) and (14) on the left
hydraulic control lever.
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BACKHOE ATTACHMENT MECHANICAL CONTROLS VERSION
Three backhoe attachment control configurations exist:

Z standard configuration;
Z ISO configuration;
Z cross-pattern configuration;
Z four-lever pattern.
The operating pattern of the control levers is different.
STANDARD CONFIGURATION
Backhoe boom and backhoe attachment swing lefthand control lever
This lever has five positions:
Position (0): neutral/hold. This position enables the
attachment movement to be stopped. As soon as the
Position (A): the boom lowers.
Position (B): the boom rises.
Position (C): the backhoe attachment swings to the
left.
Position (D): the backhoe attachment swings to the
right.
Backhoe dipper and backhoe bucket right-hand
control lever
Position (E): the backhoe dipper extends.
Position (F): the backhoe dipper retracts.
Position (G): the backhoe bucket closes.
Position (H): the backhoe bucket opens.
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ISO CONFIGURATION
Lever for backhoe dipper and backhoe attachment swing
Position (A): the backhoe dipper extends.
Position (B): the backhoe dipper retracts.
left.
right.
Backhoe boom and backhoe bucket right-hand
control lever
Position (E): the boom lowers.
Position (F): the boom rises.
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CROSS-PATTERN CONFIGURATION
Backhoe boom and backhoe attachment swing
left-hand control lever
left.
right.
control lever
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Four-lever pattern configuration

Lever (1) for dipper
This lever has three positions:
Position (A): the backhoe dipper extends.
Position (B): the backhoe dipper retracts.
Lever (2) for boom
Position (C): the boom rises.
Position (D): the boom lowers.
Lever (3) for backhoe bucket
Position (E): the backhoe bucket closes.
Position (F): the backhoe bucket opens.
Lever (4) for backhoe attachment swing
Position (G): the backhoe attachment swings to the
right.
Position (H): the backhoe attachment swings to the
left.
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STABILIZER MECHANICAL CONTROLS

Left-hand stabilizer left-hand control lever
Position (0): neutral. This position stops the movement of the left-hand stabilizer. As soon as the lever
is released, it automatically returns to the neutral position (0) and the left-hand stabilizer stops raising or
lowering.
Position (1): the left-hand stabilizer lowers.
Position (2): the left-hand stabilizer rises.
Right-hand stabilizer right-hand control lever
Position (0): neutral. This position stops the movement of the right-hand stabilizer. As soon as the lever
is released, it automatically returns to the neutral position (0) and the right-hand stabilizer stops raising or
lowering.
Position (1): the right-hand stabilizer lowers.
Position (2): the right-hand stabilizer rises.
NOTE: to raise or lower the stabilizers at the same
time, operate the two levers simultaneously.
TELESCOPIC DIPPER MECHANICAL CONTROL
PEDAL
This pedal has three positions:
Position (0): neutral. This position enables the movement of the telescopic dipper to be stopped.
NOTE: the pedal automatically returns to this position as soon as it is released.
Position (1): the telescopic dipper extends.
Position (2): the telescopic dipper retracts.
AUXILIARY ATTACHMENT CONTROL PEDAL
(Optional)
This pedal (1) is located to the right of the backhoe
attachment controls and is used for operating auxiliary attachment, such as a hydraulic hammer.
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3.
BACKHOE ATTACHMENT HYDRAULIC CONTROLS
BACKHOE CONTROLS
Backhoe boom and backhoe attachment swing
left-hand hydraulic control lever
This control lever has five positions:
Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as released, it automatically returns to the neutral position
(0) and the attachment remains in the position where
it was when movement stopped.
left.
right.
control lever
This control lever has five positions:
Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as released, it automatically returns to the neutral position
(0) and the attachment remains in the position where
it was when movement stopped.
STABILIZER CONTROLS
These controls are located on the left-hand hydraulic
control lever and may be operated independently or
simultaneously.
Left-hand control lever for left-hand stabilizer
This lever has four positions:
Position (0): neutral. This position stops the movement of the left-hand stabilizer. As soon as the lever is
released from positions (1) or (2), it automatically returns to the neutral position (0) and the left-hand stabilizer stops raising or lowering.
When held in position (1): the left-hand stabilizer lowers.
When held in position (2): the left-hand stabilizer rises.
Position (3): stabilizer auto-up feature.
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Right-hand lever for right-hand stabilizer

This lever has four positions:
Position (0): neutral. This position stops the movement of the right-hand stabilizer. As soon as the lever
is released from positions (1) or (2), it automatically
returns to the neutral position (0) and the right-hand
stabilizer stops raising or lowering.
When held in position (1): the right-hand stabilizer
lowers.
When held in position (2): the right-hand stabilizer
rises.
Position (3): stabilizer auto-up feature.
TELESCOPIC DIPPER CONTROLS
Press and hold down the right-hand button (1) to extend the telescopic dipper. As soon as the button is
released the dipper stops and remains in the position
it occupied when the button was released.
Press and hold down the left-hand button (2) to retract the telescopic dipper. As soon as the button is
released the dipper stops and remains in the position
it occupied when the button was released.
By pressing button (3), it is possible to set the engine
rpm to idle run disabling accelerator handle and accelerator pedal. By pressing again button (3) the engine rpm are restored and the accelerator handle
and accelerator pedal as well.
Before using these controls, make sure the telescopic dipper is mechanically unlocked.
NOTE: operating the backhoe attachment control levers and these controls simultaneously will enable
numerous possibilities of progressive functioning.
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4.
4.1
CENTER PIVOT BACKHOE ATTACHMENT DISASSEMBLY

backhoe on the ground.
SWARNING
Lower stabilizers sufficiently and however ensure

that the rear tyres are in contact with the ground to
remove the weight from the rear wheels.
IMPORTANT: the rear wheels must remain in contact with the ground.
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Fully retract telescopic dipper, where fitted.
On machines fitted with telescopic dipper install locking pin in transport hole (1).
Fully retract dipper cylinder and lower boom until

bucket is firmly resting on the ground.
Support the backhoe using suitable stand and hoist
capable of carrying 1500 Kg.
Turn off engine, then move backhoe control levers
through all operating positions to relieve pressure in
the system.
Re-check that backhoe elements are fully supported.
Disconnect all hoses that travel through the swing

bracket reach the backhoe.
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Unscrew and remove the nut (2) to disconnect the

backhoe lock (3).
Remove the snap ring (4), slide out the pin (5) and
with an hammer remove the pin (6) of the swing cylinder.
Repeat the operation with both swing cylinders. Remove the snap ring (7).
Slide out the pin (8) and by means of an hammer remove the lower pin (9) from swing bracket.
Unscrew the screw (10).

Remove the upper pin (11) of the swing support.
Now it is possible to remove the backhoe assembly.
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4.2
BACKHOE ATTACHMENT DISASSEMBLY - SIDESHIFT

backhoe on the ground.
SWARNING
Lower stabilizers sufficiently and however ensure

that the rear tyres are in contact with the ground to
remove the weight from the rear wheels.
Fully retract telescopic dipper, where fitted.
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On machines fitted with telescopic dipper install locking pin in transport hole (1).
Fully retract dipper cylinder and lower boom until

bucket is firmly resting on the ground.
Support the backhoe using suitable stand and hoist
capable of carrying 1500 Kg.
the system.
Re-check that backhoe elements are fully supported.
F30332
Disconnect all hoses that travel through the swing

bracket reach the backhoe.
Unscrew and remove the nut (2) to disconnect the

backhoe lock (3).
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Remove the snap ring (4), slide out the pin (5) and
with an hammer remove the pin (6) of the swing cylinder.
Repeat the operation with both swing cylinders. Remove the snap ring (7).
Slide out the pin (8) and with an hammer remove the
lower pin (9) from the swing support.
Unscrew the screw (10).

Remove the upper pin (11) of the swing support.
Now it is possible to remove the backhoe assembly.
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4.3
23
BACKHOE BUCKET REMOVAL
Park the machine on a flat surface.

Lower the stabilizers until they are resting on the
ground.
Place the bucket on the ground.
Remove the safety pin (1).

Slide out the pin (2).
Start the engine
Move the arm so that the hook (3) can get released
from the bucket pin (4).
Remove the backhoe bucket.
4.4
BUCKET TEETH REPLACEMENT
Move the machine to a level and firm ground.

Position the backhoe bucket so that the bucket teeth
can be replaced.
Place the direction-of-travel lever and gearshift lever
in neutral position.
Immobilize the machine by means of the parking
brake.
S WARNING S
Nobody must be in the trajectory of the tooth holder
and of the tooth to be removed.
During tooth removal, both the tooth holder and the
tooth could be unexpectedly projected, thus hitting
persons standing in their trajectory or nearby.
Projected metal chips could hit persons and cause
injury.
Remove the tooth holder (2) using a hammer and a
chisel.
Remove the tooth (1) from the tooth holder (3).
Clean the inside of the tooth holder, removing any
dirt or rust.
Insert a new tooth (1) into the tooth holder (3).
Lock the new tooth by installing the tooth holder (2).
4
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4.5
Copyright
DIPPER REMOVE
Park the machine on a level, firm surface and position the backhoe on the ground.
SWARNING
Lower stabilizers sufficiently to remove the weight

from the rear wheels.
Install the locking pin in transport hole (1) [on machines fitted with telescopic dipper].
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Lower the backhoe to the ground and support using

a suitable stand.
the system.
Disconnect the hoses to the dipper cylinders:

Z Telescopic dipper hoses.
Z Standard dipper hose.
Support the dipper cylinder, unscrew and remove the

screw (2), slide out the pin (3).
Lower cylinder onto boom. Use suitable cylinder supports to ensure weight of cylinder does not damage
hydraulic tubes attached to the dipper.
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Support the dipper using suitable hoist. Unscrew and

remove the screw (4), slide out the pin (5) and carefully lower dipper to the ground.
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5.
TELESCOPIC DIPPER REVISION
INSPECTION OF GUIDE PADS

Park the machine on level ground and retract the telescopic dipper.
Position the dipper on a suitable stand with the bucket raised from the ground.
Clean the area around the pads.
Inspect each upper guide pad and if the chamfered

edge (1) on the corner of the pads is no longer visible
the pads have worn beyond their limit and must be
replaced.
If pads do not require replacement visually check if
the gap between the inner part of the dipper and upper guide pad is greater than 1.5 mm.
If the gap is greater than 1.5 mm the guide pads must
be adjusted.
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ADJUSTMENT OF GUIDE PADS

Position the dipper in the vertical position.
Count the number of shims behind the adjusting
screws on the left and right hand sides of the dipper
to determine which side has the most shims.
Remove one shim from behind an adjusting screw
on the side of the dipper which contains the most
shims.
Refit the screw and tighten to a torque of 350 400 Nm. Do NOT over torque the bolt.
Repeat the procedure for the remaining three screws
on the same side of the dipper.
Recheck the gap.
If the gap remains greater than 1.5 mm remove a
shim from behind each of the adjusting screws on the
opposite side of the dipper.
After performing an adjustment apply a coat of Dry
Moly-coat grease to the slide rails of the dipper.
NOTE: when all shims have been removed the guide
pads must be replaced.
REPLACEMENT OF GUIDE PADS
To replace the guide pads it is necessary to separate
the inner and outer parts of the telescopic dipper using either of the following procedures which are dependent on workshop facilities.
Procedure No. 1
Park the machine on level ground and lower loader
bucket.
Lower stabilizers sufficiently to remove the weight
from the rear wheels.
Position the dipper on a suitable stand.
Attach hoist to inner part of the dipper.
Disconnect the hose connections to the bucket and
the telescopic dipper cylinders.
Remove telescopic dipper cylinder pin (1) and separate inner and outer parts of telescopic dipper.
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Unscrew and remove the screws (2).

Remove the guide pads (3). Install new guide pads
and apply some thread sealant No. 82995773 to the
retaining screws. Tighten to a torque of 29 - 31 Nm.
Do not over tighten or damage to the threaded inserts may occur.
Re-assemble inner and outer parts of telescopic dipper.

Place 5 shims beneath the heads of each adjusting
screw.
Adjust guide pads as described previously.
Procedure No. 2
This procedure requires the use of a loading dock or
service pit.
Park the machine with backhoe positioned over loading dock or service pit.
Place the loader bucket on the ground and lower stabilizers sufficiently to remove the weight from the
rear wheels.
Attach suitable hoist to top of inner section of dipper
and position boom so that dipper is hanging vertically.
Disconnect the hose connections to the bucket and
the telescopic dipper cylinders.
Remove the telescopic dipper cylinder retaining pin.
Slowly lower hoist allowing inner and outer parts of
telescopic dipper to separate.
Unscrew and remove the screws (2).

Remove the guide pads (3). Install new guide pads
and apply thread sealant to the retaining screws.
Tighten to a torque of 29 - 31 Nm. Do not over tighten
or damage to the threaded inserts may occur.
Position new lower guide pads in the outer part of the
telescopic dipper.
Re-assemble inner and outer parts of telescopic dipper.
Place 5 shims beneath the heads of each adjusting
screw.
Adjust guide pads as described previously.
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Print No. 87643852B

CNH ITALIA S.p.A.

COMPLETE HANDBOOK FOR INSTRUCTIONS

Service Manual - Loader backhoe

580SR / 580SR+ / 590SR / 695SR

Service Manual - Engine

580SR / 580SR+ / 590SR / 695SR

CNH ITALIA S.p.A.

LOADER BACKHOE MODELS

Stabilizer center pivot

Engine 72 kW-97 HP model

Engine 72 kW-97 HP model

Engine 82 kW-110 HP model

Engine 82 kW-110 HP model

SECTION 00 - SAFETY PRECAUTIONS

SECTION 17 - TORQUE CONVERTERS

SECTION 25 - FRONT AXLES

SECTION 27 - REAR AXLE

SECTION 33 - BRAKES SYSTEM

SECTION 35 - HYDRAULIC SYSTEM

5.4 BACKHOE BOOM CYLINDER ............................................................................................................ 79

SECTION 41 - STEERING SYSTEM

SECTION 50 - CAB HEATING AND AIR CONDITIONING

3.8 COMPONENTS OVERHAUL .............................................................................................................. 48

SECTION 55 - ELECTRICAL SYSTEM

7.6 CONNECTING A BOOSTER BATTERY ........................................................................................... 165

SECTION 00 - SAFETY PRECAUTIONS

This warning symbol points out important messages

Z For electrical heaters, battery-chargers and similar

Z Whenever there is the possibility of being reached

Z Always disconnect the batteries before performing

IMPORTANT ECOLOGICAL CONSIDERATIONS

All maintenance and repair operations described in

Clean the exterior of all components before carrying

O-RING FLAT FACE SEAL FITTINGS

Z place the sealing lip towards the fluid. In case of a

NOTES FOR SPARE PARTS

LOADER BACKHOE MODELS

Stabilizer center pivot

Engine 72 kW-97 HP model

Engine 72 kW-97 HP model

Engine 82 kW-110 HP model

Engine 82 kW-110 HP model

IDENTIFICATION OF MAIN COMPONENTS

SIDESHIFT VERSION (590SR for example)

Dipper or telescopic dipper

CENTER PIVOT VERSION (695SR for example)

Backhoe attachment boom

2WD/2WS TRANSMISSION - POWERSHUTTLE (580SR)

2WS ..............................................................................................................................................2 wheel steer

Weight ..................................................................................................................................................... 160 kg

NOISE AND VIBRATION LEVELS

6x1 (with forks)

320/80 R18 IT 520

480/80 R26 IT520

DIMENSIONS AND PERFORMANCE

LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE

580SR / 580SR+ / 590SR

SECTION 02 - TECHNICAL SPECIFICATIONS