Case 580SR Service Manual
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Case 580SR Service Manual

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Table of Contents

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Service
manual
580SR
580SR+
590SR
695SR
SERIES 3
Print No. 87643852B
580SR
580SR+
590SR
695SR
SERIES 3
Service manual
Print No. 87643852B
Copyright ©

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Summary of Contents for Case 580SR

  • Page 1 Copyright © Service manual 580SR 580SR+ 580SR 590SR 580SR+ 695SR 590SR 695SR SERIES 3 SERIES 3 Service manual Print No. 87643852B Print No. 87643852B...
  • Page 2 www.maskinisten.net Copyright © SPICER OFF-HIGHWAY AXLE DIVISION...
  • Page 3 Viale delle Nazioni, 55 41100 MODENA - Italy Read carefully this manual to collect correct infor- mation relevant to repair procedures. For any question or remark, or in case of any error relevant the contents of this manual, please con- tact: REFERENCE...
  • Page 4 www.maskinisten.net Copyright © 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.
  • Page 5 Copyright © 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 Rops Pilot control Mechanical control Engine 72 kW-97 HP model...
  • Page 6 www.maskinisten.net Copyright ©...

  • Page 7: Table Of Contents

    www.maskinisten.net Copyright © 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 ..............................
  • Page 8 www.maskinisten.net Copyright © 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......................
  • Page 9 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 1. REAR AXLE 2WS ............................3 1.1 DESCRIPTION AND OPERATION....................... 3 1.2 SPECIFICATIONS ..........................6 1.3 DISASSEMBLY AND ASSEMBLY......................8 1.4 FAULT FINDING..........................27 2. REAR AXLE 4WS “CARRARO”........................28 2.1 SPECIFICATIONS ..........................28 2.2 DISASSEMBLY AND ASSEMBLY.......................
  • Page 10 www.maskinisten.net Copyright © 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..........................
  • Page 11 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........................
  • Page 12 www.maskinisten.net Copyright © 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.......................
  • Page 13 Copyright © 580SR 580SR+ 590SR 695SR SECTION 00 - SAFETY PRECAUTIONS...
  • Page 14 www.maskinisten.net Copyright © SECTION 00 - SAFETY PRECAUTIONS...

  • Page 15: Section 00 - Safety Precautions

    www.maskinisten.net Copyright © SECTION 00 - SAFETY PRECAUTIONS This warning symbol points out important messages involving personal safety. Carefully read the safety rules contained herein and follow advised precautions to avoid potential haz- ards and safeguard your safety and personal integ- rity.
  • Page 16 In case of operations Z Never check or fill fuel tanks and accumulator batter- outside the workshop, drive the machine to a flat ies, nor use starting liquid if you are smoking or near area and block it.
  • Page 17 Z Do not fill up fuel tank when the engine is running, Z Deflate the tyre before removing any object caught mainly if it is hot, to avoid ignition of fires in case of into the tyre tread. fuel spilling.
  • Page 18 www.maskinisten.net Copyright © SECTION 00 - SAFETY PRECAUTIONS IMPORTANT ECOLOGICAL CONSIDERATIONS The following are recommendations which may be of assistance: Z Become acquainted with and ensure that you un- derstand 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...

  • Page 19: Section 01 - Maintenance

    Copyright © 580SR 580SR+ 590SR 695SR SECTION 01 - MAINTENANCE...
  • Page 20 www.maskinisten.net Copyright © SECTION 01 - MAINTENANCE...
  • Page 21 www.maskinisten.net Copyright © SECTION 01 - MAINTENANCE All maintenance and repair operations described in Kinked, crushed, stretched or deformed hoses gener- this manual should be carried out exclusively by au- ally suffer internal structural damage which can result thorized workshops. All instructions detailed should be in oil restriction, a reduction in the speed of operation carefully observed and special equipment indicated and ultimate hose failure.
  • Page 22 Copyright © SECTION 01 - MAINTENANCE Z place the sealing lip towards the fluid. In case of a NOTES FOR SPARE PARTS hydrodynamic lip, consider the shaft rotation direc- Only genuine parts guarantee same quality, life, tion and orient grooves in order that they deviate safety as original components as they are the same the fluid towards the inner side of the seal;...

  • Page 23: Section 02 - Technical Specifications

    Copyright © 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 ..............................
  • Page 24 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS...

  • Page 25: Loader Backhoe Models

    Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS LOADER BACKHOE MODELS 580SR 580SR+ 590SR 695SR Powershift Powershuttle Stabilizer sideshift Stabilizer center pivot Rops Pilot control Mechanical control Engine 72 kW-97 HP model F4GE948C*601 (mechanical) Engine 72 kW-97 HP model F4HE0484C*J102 (electronic)

  • Page 26: Identification Of Main Components

    www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS IDENTIFICATION OF MAIN COMPONENTS SIDESHIFT VERSION (590SR for example) 1. Loader bucket 9. Dipper or telescopic dipper 2. Loader arm 10. Backhoe bucket 3. Front axle 11. Backhoe attachment sideshift carriage 4. Fuel tank 12.
  • Page 27 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS CENTER PIVOT VERSION (695SR for example) 1. Loader bucket 8. Backhoe attachment boom 2. Loader arm 9. Dipper or telescopic dipper 3. Front axle 10. Backhoe bucket 4. Fuel tank 11. Stabilizers 5.

  • Page 28: Specifications

    Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS SPECIFICATIONS 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 ............................
  • Page 29 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS Supply Type ........................high-pressure, common rail Injection pump......................CP3 high-pressure pump Control unit..............................EDC7 Injection sequence ..........................1-3-4-2 Cold-start device ......................“grid heater” (optional) Cooling Pump type............................H O pump Pump drive............................belt drive Temperature switch (opening start)..................... 81 ± 2 °C 82 kW - 110 HP ENGINE (590SR / 695SR) Specifications (EEC 88/195) ................

  • Page 30: Transmission

    3rd forward travel ..............gear 1.408:1 reverse travel gear 1.173:1 4th forward travel ..............gear 0.792:1 reverse travel gear 0.660:1 4WD/2WS TRANSMISSION - POWERSHUTTLE (580SR+ / 590SR) 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...

  • Page 31: Axles

    SECTION 02 - TECHNICAL SPECIFICATIONS 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...

  • Page 32: Steering

    Pressure relief valve adjustment ......................170 bar 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 cm...

  • Page 33: Noise And Vibration Levels

    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.........................

  • Page 34: 3.10 Tyres

    www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS 3.10 TYRES TYRE TYPES Tyres - 2WS Front tyres Rear tyres 11L-16 F3 12PR 18.4-26 R4 12PR 11L-16 F3 12PR 16.9-28 R4 12PR 12.5/80 - 18 L3 10PR 18.4-26 R4 10PR 12.5/80 - 18 L3 10PR 16.9-28 R4 10PR 320/80 R18 IT 520 480/80 R26 IT520...

  • Page 35: Dimensions And Performance

    Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS DIMENSIONS AND PERFORMANCE LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE 580SR / 580SR+ / 590SR A. Maximum height B. Maximum height of loader bucket pin/pivot C. Maximum dumping height D. Angle of lowered closed bucket E.
  • Page 36 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS TYRES FRONT REAR 11L-16F 18.4-26 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...
  • Page 37 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS 695SR (SIDESHIFT) A. Maximum height B. Maximum height of loader bucket pin/pivot C. Maximum dumping height D. Angle of lowered closed bucket E. Angle of closed bucket at maximum height F. Loader attachment reach when raised in dump- ing position G.
  • Page 38 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS TYRES FRONT REAR 440/80R28 440/80R28 6x1 bucket (with Dimensions Standard bucket Bucket 4x1 forks) 4347 mm 4460 mm 4460 mm 3491 mm 3518 mm 3518 mm 2717 mm 2753 mm 2753 mm 45°...
  • Page 39 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS 695SR (CENTER PIVOT) A. Maximum height B. Maximum height of loader bucket pin/pivot C. Maximum dumping height D. Angle of lowered closed bucket E. Angle of closed bucket at maximum height F. Loader attachment reach when raised in dump- ing position G.
  • Page 40 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS TYRES FRONT REAR 16.9-28 16.9-28 6x1 bucket (with Dimensions Standard bucket Bucket 4x1 forks) 4347 mm 4460 mm 4460 mm 3491 mm 3518 mm 3518 mm 2717 mm 2753 mm 2753 mm 45°...

  • Page 41: Dimensions And Performance Of Loader Attachment With Forks

    Fork spacing - Maximum centres ......................1773 mm Fork length ............................1026 mm Fork width ............................... 80 mm 580SR / 580SR+ / 590SR A. Reach full height ........................... 2319 mm B. Reach ground level ........................3186 mm C. Lift height ............................2998 mm D.

  • Page 42: Backhoe Attachment Dimensions And Performance

    Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE 580SR / 580SR+ / 590SR A. Maximum reach when loaded B. Bucket rotation C. Operating height, fully raised D. Maximum height at full load E. Reach from swing post F.
  • Page 43 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS TYRES 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...
  • Page 44 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS 695SR (SIDESHIFT) A. Maximum reach when loaded B. Bucket rotation C. Operating height, fully raised D. Maximum height at full load E. Reach from swing post F. Reach from rear axle centre line G.
  • Page 45 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS TYRES FRONT REAR 440/80R28 440/80R28 Dimensions standard dipper telescopic dipper (extended) 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...
  • Page 46 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS 695SR (CENTER PIVOT) A. Maximum reach when loaded B. Bucket rotation C. Operating height, fully raised D. Maximum height at full load E. Reach from swing post F. Reach from rear axle centre line G.
  • Page 47 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS TYRES FRONT REAR 440/80R28 440/80R28 Dimensions standard dipper telescopic dipper (extended) 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...

  • Page 48: Backhoe Attachment Lifting Capacity

    Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS 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).
  • Page 49 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS 695SR (SIDESHIFT) 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 ac- cessories mounted, the pressure settings and the market requirements.
  • Page 50 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS 695SR (CENTER PIVOT) 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 ac- cessories mounted, the pressure settings and the market requirements.

  • Page 51: Maximum Lifting Loads

    www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS MAXIMUM LIFTING LOADS LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE...

  • Page 52: Backhoe Attachment Maximum Lifting Load Table

    www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE...

  • Page 53: Supply Summary Table

    Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS SUPPLY SUMMARY TABLE QUANTITY RECOMMENDED FLUIDS AND CASE INTERNATIONAL MODELS APPLICATION Specifications Specifications Litres ENGINE - OIL Akcela No 1 Engine oil (15W40) MA 1121 API CH-4, ACEA E5 2WS - with filter 4WS - with filter 12.8...
  • Page 54 www.maskinisten.net Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS NOTES:...

  • Page 55: Section 17 - Torque Converters

    Copyright © 580SR 580SR+ 590SR 695SR 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............................
  • Page 56 www.maskinisten.net Copyright © SECTION 17 - TORQUE CONVERTERS...

  • Page 57: Powershuttle Torque Converter

    www.maskinisten.net Copyright © SECTION 17 - TORQUE CONVERTERS POWERSHUTTLE TORQUE CONVERTER DESCRIPTION AND OPERATION The torque converter is the connection between the engine and the transmission and is hydraulically ac- tuated. The main parts of the torque converter (A) are the impeller (pump), the turbine, the stator and the front and rear covers.

  • Page 58: Specifications

    www.maskinisten.net Copyright © SECTION 17 - TORQUE CONVERTERS 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 ..........................

  • Page 59: Disassembly And Assembly

    www.maskinisten.net Copyright © SECTION 17 - TORQUE CONVERTERS 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.

  • Page 60: Fault Finding

    www.maskinisten.net Copyright © SECTION 17 - TORQUE CONVERTERS 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 rear- ward position.

  • Page 61: Powershift Torque Converter

    www.maskinisten.net Copyright © SECTION 17 - TORQUE CONVERTERS POWERSHIFT TORQUE CONVERTER DESCRIPTION AND OPERATION 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.

  • Page 62: Specifications

    www.maskinisten.net Copyright © SECTION 17 - TORQUE CONVERTERS 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 Tachometer setting ..........................2200 rpm Test temperature, oil ..........................

  • Page 63: Inspection

    www.maskinisten.net Copyright © SECTION 17 - TORQUE CONVERTERS 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.
  • Page 64 www.maskinisten.net Copyright © SECTION 17 - TORQUE CONVERTERS 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.

  • Page 65: Stall Test

    www.maskinisten.net Copyright © SECTION 17 - TORQUE CONVERTERS STALL TEST The purpose of this test is to determine if the torque NOTE: if the unit creeps forward and the gears converter and hydraulic clutch assemblies are oper- clash, the front clutch is at fault. The rear clutch is at ating satisfactorily.

  • Page 66: Fault Finding

    www.maskinisten.net Copyright © SECTION 17 - TORQUE CONVERTERS FAULT FINDING PROBLEM CAUSE CORRECTION Low stall speed Hydraulic clutch not releasing Replace the torque converter. Stator support broken Replace the torque converter. Defective torque converter Replace the torque converter. Low engine power Check and correct output.
  • Page 67 Copyright © 580SR 580SR+ 590SR 695SR 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........
  • Page 68 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION...
  • Page 69 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 hy- draulic clutch assemblies in the transmission (3).
  • Page 70 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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...........................
  • Page 71 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...
  • Page 72 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION TRANSMISSION CONTROLS 4x4 POWERSHUTTLE TRANSMISSION CONTROLS 1. GEAR LEVER: it is possible to select four for- 5. ROLLER FOR THE PROPORTIONAL CON- ward and four rearward travel gears. TROL OF LOADER BUCKET 4x1 2.
  • Page 73 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 col- umn mounted powershuttle lever (4) enables shifts between forward and reverse travel without disen- gaging gear ratios.
  • Page 74 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Forward/reverse powershuttle lever To select FORWARD travel, engage the required gear ratio with the gearshift lever, then with the en- gine 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.
  • Page 75 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Transmission disconnection The 4x4 transmission provides for easy upward and downward gear ratio changes on the move. Howev- er, 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.
  • Page 76 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION IMPORTANT: operating at a “stall” for more than 20 seconds can cause the transmission to overheat and can possibly damage the transmission. If the trans- mission overheats, the indicator needle (1) moves to the red zone.
  • Page 77 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 78 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION TRANSMISSION OIL FLOW AND SUPPLY F29967 Pressure oil Disengaged Lubrication...
  • Page 79 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION OIL FLOW AND SUPPLY IN NEUTRAL POSITION F29968 Pump pressure Lubrication Return to Sump Suction Torque converter flow 1. Powershuttle control solenoid valve oil 14 bar. 6. Cold start pressure protection valve - prevents 2.
  • Page 80 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION OIL FLOW AND SUPPLY IN FORWARD POSITION F29969 Pump pressure Lubrication Return to Sump Suction Torque converter flow 1. Returned lubrication oil from the pump shaft 6. Torque Converter oil OUT, to oil cooler. bush to tank.
  • Page 81 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION TRANSMISSION OIL SUPPLY PORT Viewed from front and rear housings 1. Oil supply port to reverse clutch pack, rear cas- 12. Oil supply from pump to solenoid valve pack. ing. 13. Oil supply port to reverse clutch pack, front cas- 2.
  • Page 82 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 83 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 84 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 9. Oil flow IN from cooler 26 bar reference only 10.
  • Page 85 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION TRANSMISSION POWER FLOW When neutral is selected on the powershuttle lever (1), the transmission forward (3) and reverse hydrau- lic 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...
  • Page 86 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION F29980 Input Output Intermediate...
  • Page 87 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION NOTE: 4WD shown.
  • Page 88 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION NOTE: 4WD version shown.
  • Page 89 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION TRANSMISSION 2WD COMPONENTS F27510...
  • Page 90 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION F27511...
  • Page 91 Copyright © SECTION 21 - TRANSMISSION 1. Front gear case assembly 68. Clutch pack retaining clip 2. Rear gear case assembly 69. Clutch pack retaining plate 3. Plug and O-ring 70. Clutch plate 4. Cold start spring housing 71. Clutch plate (friction) 5.
  • Page 92 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION TRANSMISSION 4WD COMPONENTS F27512...
  • Page 93 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION...
  • Page 94 Copyright © SECTION 21 - TRANSMISSION 1. Front gear case assembly 70. Clutch plate - steel 2. Rear gear case assembly 71. Clutch plate - friction 3. Plug assembly 72. Circlip 4. Screw 73. Spring retainer 5. Screw 74. Piston return spring 7.
  • Page 95 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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...
  • Page 96 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION SOLENOID VALVE COMPONENTS 1. Solenoid retainer 12. Circlip 2. Dust seal 13. Clutch fill metering valve 3. Solenoid 14. Spring 4. Washer 15. Spool 5. Solenoid body 16. Piston clutch fill 6. Guide 17.
  • Page 97 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 suita- ble containers for disposal. Prior to separating the transmission from the engine.
  • Page 98 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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. Re- move 3 screws and withdraw the gearshift lever as- sembly.
  • Page 99 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 100 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.
  • Page 101 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the reverse idler shaft assembly. Remove the by-pass plug, the spring and the ball. Ensure both synchronizers are in the neutral posi- tion 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.
  • Page 102 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 103 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 104 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Using a strap wrench remove and discard the oil fil- ter. 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).
  • Page 105 Copyright © SECTION 21 - TRANSMISSION Remove and discard the expansion plug from the shimming access hole. Invert the case. Remove 4 screws and copper wash- ers then withdraw the pump assembly and the seal- ing ring.
  • Page 106 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 re- move the rear bearing. Remove the thrust washer and needle bearing.
  • Page 107 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 108 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 109 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Invert the shaft and remove the sealing ring. Repeat steps described above to dismantle the for- ward clutch pack. Remove and discard the piston sealing rings and the O-rings.
  • Page 110 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 111 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 112 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Using an appropriately sized tube replace the bear- ing. 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.
  • Page 113 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 coun- tershaft front and the rear bearings.
  • Page 114 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION DISASSEMBLY AND RE-ASSEMBLY OF THE REVERSE IDLER SHAFT The reverse idler assembly. Using the appropriate bearing puller 380002683 re- move the front and the rear bearings. Using an appropriately sized tube replace the front and the rear bearings.
  • Page 115 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION OUTPUT SHAFT DISASSEMBLY Position the shaft assembly in a soft jawed vice as shown. Using the appropriate bearing puller 380002686 re- move the front bearing. Refit the 4th gear and the thrust washer. Remove the 3rd/4th synchro assembly.
  • Page 116 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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).
  • Page 117 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 118 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the bearing sleeve, the synchro hub and the 2nd gear.
  • Page 119 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 spac-...
  • Page 120 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 spac- er is fitted instead of the gear).
  • Page 121 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Refit the 3rd/4th synchronizer assembly. Refit the 4th gear and the thrust washer. Using an appropriately sized tube replace the front bearing.
  • Page 122 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION HYDRAULIC DOG CLUTCH 4WD DISASSEMBLY The hydraulic dog clutch 4WD assembly. Position the shaft in a soft jawed vice and remove the sealing ring. Using the appropriate bearing puller 380002685 re- move the rear bearing. Remove the thrust washer.
  • Page 123 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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. Using the appropriate tool 380002692 compress the spring and release the circlip.
  • Page 124 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Replace the spring, the retainer and the circlip. 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.
  • Page 125 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 126 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Using the appropriate tool 80002692 compress the spring and retainer and refit the circlip. Using an appropriately sized tube refit the front bear- ing. Invert the shaft and refit the two needle bearings and spacer as shown.
  • Page 127 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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).
  • Page 128 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION PERMANENT 4WD SHAFT ASSEMBLY The permanent 4WD shaft. Using the appropriate bearing puller 380002685 re- move the front and the rear bearings. Remove the 4WD gear.
  • Page 129 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION PERMANENT 4WD SHAFT ASSEMBLY Replace the 4WD gear using Loctite 649, or equiva- lent, on the shaft splines. Then using a suitably sized tube refit the front and the rear bearings.
  • Page 130 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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. Using the appropriate bearing puller 380002685 re- move the rear bearing.
  • Page 131 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the 4WD gear. Remove the needle bearings and the spacer. Remove the needle bearing and the thrust washer. Remove the clutch pack retaining clip.
  • Page 132 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the clutch pack retaining plate. Remove the clutch pack. Using the appropriate tool 380002690 compress the piston return spring and release the circlip. Remove the clip retainer and the spring.
  • Page 133 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 134 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION HYDRAULIC MULTI PLATE CLUTCH 4WD SHAFT ASSEMBLY Using an appropriately sized tube refit the front bear- ing. Replace the piston sealing rings to facilitate assem- bly: the seals may be warmed in lukewarm water pri- or to assembly.
  • Page 135 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Using the appropriate tool 380002690 compress the piston return spring and locate the circlip into its groove. Replace an externally splined (plain) disc then an in- ternally splined (friction) disc alternately until 8 plain discs and 8 friction discs have been fitted.
  • Page 136 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 bear- ing.
  • Page 137 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 com- pleted).
  • Page 138 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION THE OIL PUMP DISASSEMBLY AND ASSEMBLY Individual components of the oil pump are non serv- iceable. 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 appro- priately sized tube.
  • Page 139 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION DIRECTION CONTROL VALVE DISASSEMBLY AND ASSEMBLY Disassembly of the control valve is not generally rec- ommended 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.
  • Page 140 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 141 To prevent possible contamination of hydraulic parts lint or cotton rags should not be used. Position the front case as shown and using a suita- bly 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).
  • Page 142 Copyright © SECTION 21 - TRANSMISSION Invert the case and then refit the bearing cups if pre- viously 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.
  • Page 143 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 dum- my 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.
  • Page 144 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...
  • Page 145 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.
  • Page 146 (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.
  • Page 147 Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 148 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Replace the spacer, the 4WD yoke, the O-ring, the washer and the bolt. Then tighten to a torque of 68- 88 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.
  • Page 149 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Refit the temperature sender and tighten to a torque of 20-27 Nm. Ensure the 4 O-rings are in place then refit the con- trol valve assembly, tighten the 4 cap screws to a torque of 6.8 to 8.5 Nm.
  • Page 150 Apply a bead of RTV joint compound (Loctite 5900) to the gear case. Refit the gear lever assembly and tighten the three bolts to a torque of 16-24 Nm. Refit the filter housing and gasket. Tighten the two bolts to a torque of 45-64 Nm.
  • Page 151 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 con- tact.
  • Page 152 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 153 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 4WD pressure test point. Pressure should be 12.5 to 15.5 bar at maximum en- gine speed. (Approximately 2500 rpm). Converter relief pressure test point. Pressure should not exceed 7.5 bar at maximum en- gine speed.
  • Page 154 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION PARKING BRAKE The caliper assembly is mounted directly onto the rear face of the transmission housing. 1. Mounting face 2. Locknut 3. Mounting bolt 4. Outer locknut A. Adjust the two mounting bolts and locknuts to leave a 0.25/1.50 mm gap between the locknut and sleeve.
  • Page 155 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Brake pad replacement Remove the retaining spring clip. Withdraw the friction pads.
  • Page 156 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 1.12 FAULT FINDING PROBLEM CAUSE Transmission fails to drive in Low or no pump pressure. either direction Low or no oil in transmission. Mechanical failure in transmission. Worn or broken input shaft seal rings. Pressure relief solenoid valve faulty.
  • Page 157 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Low pump 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. High pump pressure Pressure relief solenoid valve faulty.
  • Page 158 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 159 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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...
  • Page 160 Copyright © SECTION 21 - TRANSMISSION POWERSHIFT TRANSMISSION “DANA T16000” This transmission is used only on powershift loader backhoe models 580SR+ / 590SR / 695SR. F27718 SPECIFICATIONS HYDRAULIC SPECIFICATIONS Suitable for operation from ambient to 120 °C continuous operating temperature.
  • Page 161 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION CONTROLS 4X2 POWERSHIFT TRANSMISSION CONTROL 1. POWERSHIFT TRANSMISSION GEARSHIFT 5. ROLLER FOR THE PROPORTIONAL CON- AND DIRECTION LEVER: four gears are se- TROL OF LOADER BUCKET 4x1 lectable for the required ground speed in for- 6.
  • Page 162 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Powershift 4x2 (EGS) transmission display - Forward travel selection...
  • Page 163 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Powershift 4x2 (EGS) transmission display - Reverse travel selection...
  • Page 164 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Powershift lever display - (LEDs) LEDs - Numbered 1 to 4: Indicate the direction of travel by the colour of the Forward = Green Neutral = Red Reverse = Orange and they also indicate the selected gear. STEADILY ILLUMINATED LED: indicates selected transmission gear.
  • Page 165 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 se- lects N2 and goes to the Neutral lock state.
  • Page 166 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Selecting neutral position At power up, “Neutral and 2nd Gear” are automati- cally selected regardless of the powershift lever po- sition (1). The LED-2 and the LED-N are illuminated in RED (neutral, 2nd) and the microprocessor is in a neutral lock state.
  • Page 167 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Upshifting Upshifting is achieved by turning the handgrip coun- terclockwise (+) 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 de- layed for 2 seconds.
  • Page 168 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 169 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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;...
  • Page 170 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Speed Ranges The microprocessor controlling the powershift trans- mission is pre-programmed to control the speed at which the gearshifts take place. This effectively protects the transmission from ex- cess forces, should gearshifts be selected at higher speeds than is desirable.
  • Page 171 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 av- erage environment and duty cycle condition.
  • Page 172 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION PRESSURE SPECIFICATIONS AND CHECK POINTS Normal operating temperature 70 - 120 °C meas- Filter by-pass valve set to 4.1 - 5 bar (*). ured at temperature check port to cooler. Lube pressure (*) 0.3 - 0.5 bar at 47 l/min pump flow Maximum allowed transmission...
  • Page 173 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION F27719 C. Left side view 11. To cooler D. Top view 12. Pressure check port 4WD 18.9-27.5 bar 13. Pressure check port regulator pressure 19.6- 9. Pressure check port converter in 5-11 bar 23.7 bar 10.
  • Page 174 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 con- tinuous operating temperature. Must withstand a 20 bar continuous pressure and a 40 bar variable pressure.
  • Page 175 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION HYDRAULIC DIAGRAM °C °C F27722 Pressure check port Temperature check port °C 1. Operator’s compartment 18. Accumulator 2. Pressure gauge 19. Pressure booster 0 - 5.5 to 0 - 20 bar 3. Thermometer 20.
  • Page 176 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION OPERATION The transmission and hydraulic torque converter of the power train enacts an important role in transmitting en- gine 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.
  • Page 177 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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...
  • Page 178 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION THE CONVERTER AND PUMP DRIVE SECTION Engine power is transmitted from the engine fly- wheel to the impeller through the impeller cover. This element is the pump portion of the torque con- verter and is the primary component which starts the oil flowing to the other components which results in torque multiplication.
  • Page 179 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 180 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION THE RANGE CLUTCHES Once a directional clutch is engaged power is trans- mitted 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 mod- ulated to enable a smooth engagement.
  • Page 181 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 182 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION The range clutches also have modulation which op- erates 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.
  • Page 183 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION POWER FLOWS F27729 F27730 1st speed forward 2nd speed forward F27731 F27132 3rd speed forward 4th speed forward...
  • Page 184 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION F27734 F27733 1st speed reverse 2nd speed reverse...
  • Page 185 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION OPERATING VALVES AND SOLENOIDS F29986 1. Transmission sump 13. Neutral reverse solenoid 2. Transmission breather 14. 1st gear clutch 3. Suction strainer 15. Accumulator 4. Gerotor oil pump 16. Electronic modulation valve 0-5.5 bar 5.
  • Page 186 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION TORQUE CONVERTER AND COOLER SYSTEM F29987 Suction oil High pressure oil Return to oil tank Torque Converter and Lubrication Oil 1. Transmission sump 2. Transmission breather 3. Suction strainer 4. Gerotor oil pump 5.
  • Page 187 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION SERVO CONTROL PRESSURE SYSTEM F29988 Suction oil Return to oil tank High pressure oil Pilot pressure Torque Converter and Lubrication Oil Modulated pilot oil 1. Transmission sump 12. 2nd/1st Solenoid 2. Transmission breather 13.
  • Page 188 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 elec- tronic 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.
  • Page 189 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION SERVO CONTROL FORWARD THIRD GEAR 4WD ENGAGED System pressure is reduced to 5.5 bar by the pressure reducer this oil then supplies the 6 solenoids and elec- tronic modulation valve. 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.
  • Page 190 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION SERVO CONTROL REVERSE FIRST GEAR 4WD ENGAGED System pressure is reduced to 5.5 bar by the pressure reducer this oil then supplies the 6 solenoids and elec- tronic modulation valve. 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.
  • Page 191 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 192 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION F29992 Suction oil Return to oil tank High pressure oil Pilot pressure Torque Converter and Lubrication Oil Modulated pilot oil...
  • Page 193 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 194 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION F29993 Suction oil Return to oil tank High pressure oil Pilot pressure Torque Converter and Lubrication Oil Modulated pilot oil...
  • Page 195 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 196 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION F29994 Suction oil Return to oil tank High pressure oil Pilot pressure Torque Converter and Lubrication Oil Modulated pilot oil...
  • Page 197 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 198 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION GEAR AND CLUTCH LAY OUT F27735 Forward low Forward high Reverse and 1st Disconnect Input shaft...
  • Page 199 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 2.10 TRANSMISSION REMOVAL AND INSTALLATION REMOVAL WARNING Before performing any service or maintenance on the machine ensure the wheels are chocked/blocked to pre- vent 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.
  • Page 200 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 17. Disconnect the 12 pin connector from the trans- mission 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).
  • Page 201 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 at- taching bolts accessed through the starter motor aperture (1).
  • Page 202 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 203 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 2.11 TRANSMISSION COMPONENTS CONVERTER HOUSING AND TRANSMISSION...
  • Page 204 O-ring converter housing to transmission case O-ring converter housing to transmission case Gasket converter housing to transmission case Housing converter Lock washer - converter housing to transmission case screw Screw - converter housing to transmission case O-ring filter adaptor O-ring filter adaptor...
  • Page 205 Screw - oil baffle mounting Plate - oil baffle Plate - oil baffle Pin - transmission case to converter dowel Lock washer - converter housing to transmission case screw Screw - converter housing to transmission case Case - transmission O-ring...
  • Page 206 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION INPUT SHAFT, TORQUE CONVERTER, PUMP DRIVE, INTERNAL CHARGING PUMP AND DRIVE PLATE...
  • Page 207 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION ITEM DESCRIPTION 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 Seal washer - pump mounting screw...
  • Page 208 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION F27746...
  • Page 209 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION ITEM DESCRIPTION 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 Retaining ring - clutch gear bearing Bearing - clutch gear Snap ring...
  • Page 210 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION ITEM DESCRIPTION QUANTITY Snap ring spacer Thrust washer Thrust bearing Bearing - needle Gear - forward high clutch Bearing - needle Thrust bearing Thrust washer Bearing - rear forward low/forward high shaft Ring - piston...
  • Page 211 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION REVERSE / 1ST SHAFT AND GEARS 16 17 34 35 F27747...
  • Page 212 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION ITEM DESCRIPTION QUANTITY Bearing - front reverse: 1st shaft Gear - reverse driven Snap ring Bearing - clutch gear Retaining ring - clutch gear bearing Gear forward low clutch Ring - clutch gear piston Retaining ring - clutch gear bearing Bearing - clutch gear Snap ring...
  • Page 213 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION ITEM DESCRIPTION QUANTITY Retaining ring - clutch gear bearing Gear - 1st clutch Retaining ring - clutch gear bearing Bearing - clutch gear Snap ring Bearing - rear reverse / 1st shaft Ring - piston...
  • Page 214 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 2ND SHAFT F27748...
  • Page 215 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION ITEM DESCRIPTION QUANTITY Ring - piston Bearing - front 2nd shaft Washer - bearing support Bearing - clutch gear Retaining ring - clutch gear bearing Gear - 2nd clutch Retaining ring - clutch gear bearing Bearing - clutch gear Snap ring - clutch disc backing plate Plate - clutch disc backing...
  • Page 216 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION OUTPUT SHAFT WITH INTERNAL DISCONNECT F27749...
  • Page 217 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION ITEM DESCRIPTION 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 Snap ring - gear retainer Assembly - output shaft front Bushing Snap ring - clutch disc backing plate...
  • Page 218 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION PARKING BRAKE 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 Boot Oil seal...
  • Page 219 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION ITEM DESCRIPTION QUANTITY Torque plate - front Pads assembly Torque plate - rear Sleeve mounting Adjuster screw Spring...
  • Page 220 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION ELECTRICAL CONTROL VALVE F27751 ITEM DESCRIPTION QUANTITY Control valve assembly Control valve mounting screws Control valve protection cover gasket Control valve protection cover Protection cover screw Air breather...
  • Page 221 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 2.12 DISASSEMBLY AND ASSEMBLY ASSEMBLY INSTRUCTIONS F27752 1. Add some grease to O-ring before assembly. 2. Add some grease to piston rings before assem- bly slots of the piston rings are not allowed to pass bores in housings.
  • Page 222 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 3. Teflon seals must be sized prior to assembly. • Assembly see (6) Grease the inner and outer diameter of the • Clearance: clutch drum before assembly. min. clearance = 3.66 mm (for carbon plates) 4.
  • Page 223 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION TRANSMISSION DISASSEMBLY Remove the oil filter. Remove the filter adapter screws. Remove the filter adapter with the O-ring. Remove the drive plate screws.
  • Page 224 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the drive plates. Remove the torque converter assy. Remove the charging pump screws. Use a bearing puller to remove the charging pump.
  • Page 225 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the charging pump assy, remove the O- ring. Remove the parking brake mounting screws. Remove the parking brake assy. Remove the upper output nut, the washer, the O-ring and the flange.
  • Page 226 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 227 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 gas- ket.
  • Page 228 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.
  • Page 229 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).
  • Page 230 Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 231 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 232 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 233 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 234 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 235 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 236 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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. Remove the by-pass plug, the spring and the ball.
  • Page 237 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the by-pass plug, the spring and the ball.
  • Page 238 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION FORWARD HIGH CLUTCH DISASSEMBLY Remove the clutch shaft sealing rings. Remove the thrust washer and the thrust bearing. Remove the clutch gear outer needle bearing. Remove the clutch gear.
  • Page 239 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the clutch gear inner needle bearing. Remove the thrust washer and the thrust bearing. Remove the backing plate retainer ring. Remove the clutch plate spacer.
  • Page 240 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the clutch disc backing plate. Remove the one outer half disc. Remove the inner and the outer discs. Remove the one outer half disc.
  • Page 241 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 242 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the clutch piston spring. Remove the clutch piston wear plate. Remove the clutch piston assy.
  • Page 243 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 244 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Clutch the gear and the outer bearing removed. Remove the spacer snap ring. Remove the spacer. Remove the backing plate retainer ring.
  • Page 245 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the clutch disc backing plate. Use bearing puller to remove the clutch gear inner bearing. Clutch gear inner bearing removed. Remove the one outer half disc.
  • Page 246 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the inner and the outer discs. Remove the one outer half disc. Remove the clutch gear inner bearing locating ring. Compress the spring to remove the spring retainer snap ring.
  • Page 247 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the spring retainer snap ring. Remove the clutch piston spring retainer. Remove the clutch piston spring. Remove the clutch piston wear plate.
  • Page 248 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the clutch piston assy.
  • Page 249 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 250 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install the clutch piston spring retainer. 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 re- tainer ring.
  • Page 251 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 252 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install the spacer. Install the spacer snap ring. Install the inner bearing snap ring. Install the clutch gear inner bearing.
  • Page 253 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 254 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 255 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION FORWARD HIGH CLUTCH ASSEMBLY Install the clutch 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.
  • Page 256 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install the piston return spring retainer. Install the spring retainer spacer. 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 re- tainer ring.
  • Page 257 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install one outer half disc, with friction material away from the piston. Install one steel disc. Alternate friction and steel discs until the proper amount of discs are installed, first and last discs are steel.
  • Page 258 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 259 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 260 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION FIRST CLUTCH DISASSEMBLY Remove the clutch shaft sealing rings. Remove the clutch gear bearing retaining ring. Use a bearing puller to remove the clutch gear and the clutch gear outer bearing. Clutch the gear and the outer bearing removed.
  • Page 261 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the backing plate retainer ring. Remove the backing plate. Remove the modulation spring. Use bearing puller to remove the clutch gear inner bearing.
  • Page 262 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Clutch gear inner bearing removed. Remove the one outer half disc. Remove the inner and the outer discs. Remove the one outer half disc.
  • Page 263 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 264 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the clutch piston assy.
  • Page 265 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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. Use a bearing puller to remove the clutch gear and the clutch gear outer bearing.
  • Page 266 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Clutch the gear and the outer bearing removed. Remove the spacer snap ring. Remove the spacer. Remove the backing plate retainer ring.
  • Page 267 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the clutch disc backing plate. Use bearing puller to remove the clutch gear inner bearing. Clutch gear inner bearing removed. Remove the one outer half disc.
  • Page 268 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the inner and the outer discs. Remove the one outer half disc. Remove the inner bearing locating ring. Compress the spring to remove the spring retainer snap ring.
  • Page 269 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the spring retainer snap ring. Remove the clutch piston spring retainer. Remove the clutch piston spring. Remove the clutch piston wear plate.
  • Page 270 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the clutch piston assy.
  • Page 271 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION REVERSE 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.
  • Page 272 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install the clutch piston spring retainer. 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 re- tainer ring.
  • Page 273 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 274 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install the spacer. Install the spacer snap ring. Install the inner bearing snap ring. Install the clutch gear inner bearing.
  • Page 275 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 276 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 277 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION FIRST 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.
  • Page 278 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install the disc belleville washer spring retainer ring. Compress the spring to install the spring retainer ring. Be sure ring is in full position in the groove. Install one outer half disc, with friction material away from the piston.
  • Page 279 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install one outer half disc with friction material down. Install the modulator spring with large diameter up to the backing plate. Install the backing plate. Install the backing plate snap ring.
  • Page 280 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install the clutch disc hub inner bearing. Tap the 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.
  • Page 281 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Tap the outer bearing into the clutch hub. Install the outer bearing retaining ring. Install the clutch shaft sealing rings.
  • Page 282 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION SECOND CLUTCH DRUM DISASSEMBLY Press the upper output gear from the second shaft. Press the gear from second shaft. Remove the gear retaining ring. Remove the clutch shaft sealing rings.
  • Page 283 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 284 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Use a bearing puller to remove the clutch hub inner bearing. Remove the clutch hub inner bearing. Remove the backing plate snap ring. Remove the backing plate.
  • Page 285 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the modulation spring. Remove the one outer half disc. Remove the inner and the outer discs. Remove the one outer half disc.
  • Page 286 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Compress the spring to remove the spring retaining ring. Remove the spring retaining ring. Remove the spring retainer. Remove the clutch piston return spring.
  • Page 287 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the piston wear plate. Remove the clutch piston assy.
  • Page 288 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION SECOND CLUTCH DRUM ASSEMBLY Install the 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.
  • Page 289 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 290 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 modulator spring with large diameter up to the backing plate.
  • Page 291 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 292 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install the clutch hub outer bearing. WARNING Be sure that bearing shield is on the outside. Tap the outer bearing into the place. Install the bearing washer. Warm the front bearing to 120 °C, install the bearing.
  • Page 293 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install the clutch shaft sealing rings. Install the gear retaining ring. Warm the gear to 150 °C, install the gear. Warm upper output gear to 150 °C install gear.
  • Page 294 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 295 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Press the output gear from the shaft. Remove the output gear. Remove the oil baffle from the output shaft. Remove the gear retaining ring.
  • Page 296 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the backing plate snap ring. Remove the backing plate spacer. Remove the backing plate. Remove the one outer half disc.
  • Page 297 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the inner and the outer discs. Remove the one outer half disc. Compress the spring to remove the spring retaining ring. Remove the spring retaining ring.
  • Page 298 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the spring retainer. Remove the clutch piston spring. Remove the piston wear plate. Remove the piston assy.
  • Page 299 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION OUTPUT SHAFT ASSEMBLY Install the 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.
  • Page 300 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 301 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install one half disc with friction material down. Install the backing plate. Install the backing plate spacer. Install the backing plate snap ring.
  • Page 302 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install the oil baffle on the output shaft. Install the output gear retaining ring. Warm the gear to 150 °C, install the gear. Install the output gear retaining ring.
  • Page 303 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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).
  • Page 304 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 305 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Remove the clutch hub locating ring from the shaft.
  • Page 306 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 307 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install the front bearing on the shaft. Tap the bearing on the shaft.
  • Page 308 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 309 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 310 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 311 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 312 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Press the forward low gear from the shaft.
  • Page 313 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION INPUT SHAFT ASSEMBLY Install the forward low gear retaining ring. Warm the gear to 150 °C, install the gear. Install the forward low gear retaining ring. Install the input shaft front bearing retaining ring.
  • Page 314 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 315 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 316 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install the input shaft into housing and in the mean- time install reverse and first shaft (they have to be in- stalled 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.
  • Page 317 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Install the upper and the lower output at the same time. Do not force this operation, be sure discs of discon- nect are in full position. Using caution as not to dam- age any of the lower shaft sealing rings. Install the baffle plate, the mounting screws, the washers and the nuts.
  • Page 318 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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).
  • Page 319 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 320 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 321 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 hous- ing mounting screws and the lock washers.
  • Page 322 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 re- taining ring is complete in the bearing groove. (Using a lifting eye or screw M12).
  • Page 323 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Position the upper output seal. Tap the seal into the place. Install the upper output flange, the O-ring, the wash- er and the nut and tighten the nut to 339 - 407 Nm. Install the pump drive shaft assy into the housing.
  • Page 324 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 325 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 326 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 327 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.
  • Page 328 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 329 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Replacement and adjustment of parking brake 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).
  • Page 330 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 2.13 SPECIAL TOOLS P/N CNH DESCRIPTION 380000676 Lifting tool...
  • Page 331 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 slip- ping clutches, then measure clutch pack pressure to determine if the slippage is due to low pressure or clutch plate friction material failure.
  • Page 332 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION PROBLEM CAUSE CORRECTION Low clutch pressure Low oil level Fill to proper level. Clutch pressure regulating valve Clean valve spool and housing. stuck open Faulty charging pump Replace the pump. Broken or worn clutch shaft or Replace seal rings.
  • Page 333 F28292 LED display. INDICATION OF FAULTS In case a fault is present during normal operation and is detected by the microprocessor, both the T- LED and N-LED may be blinking in some way as shown in the table below.
  • Page 334 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 335 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION SHIFT LEVER INPUT FAULT CODE F1 Perform input test This test is used to verify operation of the shift lever and its inputs. Blinks Slower Blink In this mode driving is possible. Blinks Blinks NOTE: the gear position indicators on the micro- processor top cover are used to display the test in-...
  • Page 336 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Key on power T-LED Blinks No input fault N-LED Blinks Slower Select neutral and push kickdown button: = LED 1 red Other input fault = LED 4 orange Input fault: forward/reverse Check through Replace the powershift lever unit F2, F3, F4 or F11 Test with new powershift...
  • Page 337 Z 4WD braking remains operative. NOTE: that the system response in this case is iden- tical to the response in case of a power supply over- F28361 voltage. Speed sensor test using the turbine speed dis-...
  • Page 338 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Speed sensor test okay Key on power T-LED Blinks No input fault N-LED Blinks Slower Select neutral and push kickdown button: = LED 1 red = LED 1 red Other input fault = LED 5 orange (F2) = LED 5 red (F3) Check wires from speed sensor CV pin A to Powershift Refer to F1, F4...
  • Page 339 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION FAULT CODE F4 / BATTERY OVERVOLTAGE (17 V +) Over voltage Even power supply levels up to 30 V will not damage Blinks Slower Blink system components. Above a power supply of 17 Vdc: Blinks Blinks Group Fault 1 - Fault code 7.
  • Page 340 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Key on power No input fault T-LED Blinks N-LED Blinks Slower Select neutral and push kickdown Other input fault button: Check through F1, F2, F3 or 1 red - 7 green Check battery voltage above 17.7 Volts Check dual battery connection is Disconnect and...
  • Page 341 In this case the Microprocessor normally turns on the pressure modulator (E03-Pin T). This results in immediate selection of neutral regardless of the ori- gin of the fault. Indeed even in case the short to plus is applied externally, this response effectively blocks the transmission in neutral.
  • Page 342 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION During the output test LEDs 1234567 one by one are used and by colour identifies the possible component at fault. Green= No fault Red = Short circuit found Yellow = open circuit or short to battery plus Identify component by LED Identify component by LED 1 - Forward solenoid...
  • Page 343 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 micro- processor outputs remain off until the test mode is left.
  • Page 344 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Key on power Safety critical T-LED Blinks output N-LED Blinks Faster Other output fault Select neutral and push kickdown button forced to plus (F5) open circuit: 2 red - 4 orange (F6) 2 red - 4 red All LEDs green Perform output test - fault Other LEDs are...
  • Page 345 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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 Blinks Blinks and turn ignition on. in Phase Blinks In this mode, driving is not possible, since all micro-...
  • Page 346 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Key on power T-LED Blinks Non critical output N-LED Blinks in phase fault Select neutral and push kickdown button Other output fault (F7) open circuit: 2 red - 5 orange (F8) short circuit 2 red - 5 red All LEDs green Perform output test - fault found? NO...
  • Page 347 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION FAULT CODE F9 AND F10 / DIRECTION MODULATION OUTPUT SHORT OR OPEN CIRCUIT A fault on this output is considered as a problem po- Blinks Blinks tentially reducing transmission life. in Phase Blinks For this reason while a fault is persistent, the allow- Blinks able direction change speed limit is decreased grad-...
  • Page 348 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Key on power T-LED Blinks No fault N-LED Blinks in phase Select neutral and push kickdown (F10) Other non critical button (F9) 2 red - 5 orange 2 red - 6 output fault, F7 or F8 All LEDs green Direction modulator open Direction modulator short...
  • Page 349 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION FAULT CODE F11 / START UP FAULT LIMP HOME SELECTED Internal faults Blinks Slower Blink At power up a series of integrity checks is done. If a fault is detected: Blinks Blinks Z and the fault prevent operation as a transmission controller: the microprocessor locks itself in a reset state.
  • Page 350 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION FAULTS OTHER F12 NOT IDENTIFIED BY THE LEDS There may be situations when an individual compo- nent 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.
  • Page 351 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION Key on power Perform input test and analyse faults if possible fault found Possible input switch faults: 4WD - Request Repair or Brake - Request replace Declutch - Request Direction - Request Speed/Temp sensor Key on power Perform output test and check range modulation LED 7 (wire...
  • Page 352 www.maskinisten.net Copyright © SECTION 21 - TRANSMISSION 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.
  • Page 353 Copyright © 580SR 580SR+ 590SR 695SR SECTION 25 - FRONT AXLES 1. FRONT AXLE 2WD “CARRARO” ......................... 3 1.1 SPECIFICATIONS ..........................3 1.2 DISASSEMBLY AND ASSEMBLY......................6 1.3 FAULT FINDING..........................24 2. FRONT AXLE 4WD “CARRARO” ....................... 26 2.1 SPECIFICATIONS ..........................26 2.2 DISASSEMBLY AND ASSEMBLY.......................
  • Page 354 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES...
  • Page 355 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES FRONT AXLE 2WD “CARRARO” SPECIFICATIONS TYPE Front steering axle, model 26.00 F27349...
  • Page 356 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES GREASING AND LUBRICATION DESCRIPTION POSITION Oil level plug Air breather Level, fill and drain plug for reduction gear oil Oil drain plug Greasing points...
  • Page 357 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Before draining the oil from axle housing, use the breather (2) to release possible internal pressure. WARNING Risk of violent oil ejection. To drain the oil remove the level plug (1) and the drain plug (4).
  • Page 358 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES DISASSEMBLY AND ASSEMBLY FRONT AND REAR SUPPORT F27351 Disassembly Remove the rear support (10) from the differential support. F27352...
  • Page 359 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the O-ring (11) from the rear support (10). NOTE: this is a destructive operation for the O-ring. F27353 Remove the bolt (8) with the lube nibble (9). Remove the bush (12) from the rear support (10). F27354 Remove the bushes (1) from the rear support (10).
  • Page 360 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Take the front support (2) out from the axle housing (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.
  • Page 361 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Apply sealant on the bushes (1) contact surface. Assemble the bushes (1) to the rear support (10) with a pad and a hammer. F27355 Assemble the bush (12) in the rear support (10). WARNING Align the bush hole with the bolt (8) hole.
  • Page 362 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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). NOTE: if necessary assemble the bush (4) with a pad and a hammer.
  • Page 363 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES STEERING CYLINDER F27227 Disassembly Loosen the nut (1) with enough turns till it is protrud- ing 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).
  • Page 364 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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.
  • Page 365 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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. F27233 Install the steering cylinder (7) already assembled on the central body.
  • Page 366 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Screw the locknuts (4) and (11) of the tie rods (3) and (12) only when the toe-in adjustment has been carried out. F27238...
  • Page 367 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES WHEEL HUB F27365 Disassembly Unscrew and remove the fastening screws (1) of the cover (2). Remove the cover (2) and the O-ring (6). F27366...
  • Page 368 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Loosen and remove the screws (3). Remove the thrust washer (4). Remove the wheel hub (7) using levers and a ham- mer to facilitate the operation. NOTE: collect the bearing cone (5). F27368 Position the wheel hub (7) on a flat surface and re- move the seal ring (9) with a lever.
  • Page 369 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the swivel housing (10) from the axle shaft. F27371 Remove the thrust washers (16) and (19) with the bushes (17) and (18). F27372 Assembly If it has been previously removed, reassemble the steering stop composed by the screw (15) and nut (14).
  • Page 370 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES If ball joints (21) and (22) have been previously re- moved, reassemble them on the upper (11) and low- er king pin (13). F27374 Secure the swivel housing (10) with a belt or a rope to a hoist or to any other supporting device.
  • Page 371 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the bearing cone (8) on the swivel hous- ing (10). Assemble the wheel hub (7) on the swivel housing (10) and insert the bearing cone (5). F27377 Assemble the thrust washer (4). Screw the screws (3).
  • Page 372 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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.
  • Page 373 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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 be- tween the wheel hubs diameters ends is within the requested tolerance range.
  • Page 374 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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 adjust- ment and a long bar perfectly leaned over the ma- chined part of the central body (pinion side), so that the two bars form an acute angle at the maximum steering.
  • Page 375 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Steer completely towards the other side and repeat the same operation. F27348...
  • Page 376 Vibration during forward drive, intermittent noise Incorrect installation / defective axle Correct installation or repair or replace the differential in case it does not survive any one of the test phases. Overloading / incorrect weight distribution Remove excessive weight and redistribute load, following instructions related to the vehicle.
  • Page 377 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES PROBLEM CAUSE CORRECTION Axle beam body bent Vehicle overloaded Replace axle beam body. Vehicle’s 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.

  • Page 378: Front Axle 2Wd "Carraro

    www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES FRONT AXLE 4WD “CARRARO” SPECIFICATIONS TYPE Front steering axle, model 26.16 F27203 POWERSHIFT POWERSHUTTLE RATIO • • 12.8 • 12.333 • 13.714 • 14.308...
  • Page 379 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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 Amber Note: do not use synthetic or vegetable oil without consent of the axle Mastertran NH 410 C manufacturer F27205...
  • Page 380 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Before draining the oil from axle housing, use the oil breather (2) to release possible internal pressure. WARNING Risk of violent oil ejection. To drain the oil remove the level plug (1) and the drain plug (4).
  • Page 381 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Rotate the wheel end so that the hole (3) is in the po- sition shown in figure. Fill to the bottom of the fill plug hole with specified oil. Tighten the plug (3) to the requested torque.
  • Page 382 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES MOUNTING SCREW TORQUE 165 Nm 13 Nm 95 Nm 120 Nm 8 Nm 150 Nm 95 Nm 25 Nm 120 Nm 169 Nm 80 Nm 8 Nm 300 Nm 120 Nm 120 Nm 57 Nm 266 Nm 165 Nm...
  • Page 383 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES DISASSEMBLY AND ASSEMBLY FRONT AND REAR SUPPORT F27212 Disassembly Remove the nut (3) and the bolt (2) and extract the flange (1) from the pinion shaft end (14). F27213...
  • Page 384 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Loosen the bolt (4). Take the rear support (5) out from the differential support. F27214 Remove the O-ring (6) from the bush (8) in rear sup- port (5). NOTE: this is a destructive operation for the O-ring. F27215 Remove the bolt (4).
  • Page 385 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the cover (11) from differential support with a lever. F27218 Remove the O-ring (12) and the seal ring (13) from the cover (11). NOTE: destructive operation for the seal rings. F27219 Remove the bush (9) and the thrust washer (10) from differential support only if necessary.
  • Page 386 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the bolt (19). Remove the bush (18) from the front support (20). Remove the bushes (21) from front support (20). F27222 Remove the bush (17) and the thrust washer (16) from axle housing (15) only if necessary. NOTE: it is advisable to heat the bush (17) to make easy this operation;...
  • Page 387 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the cover (11) to the differential support. F27218 Apply sealant on the bushes (6) contact surface. Assemble the bushes (6) to the rear support (5) with a pad and a hammer. F27217 Assemble the bush (8) in the rear support (5).
  • Page 388 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Insert the rear support (5) on the differential support. WARNING Do not damage the O-ring when inserting the rear support on the central body. Tighten the bolt (4) to the requested torque. F27214 Assemble the flange (2) to the pinion shaft end (14).
  • Page 389 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the bush (18) into the front support (20) with a suitable driver and a hammer. WARNING Align the bush hole with the bolt (19) hole. Mount the bolt (19). F27225 Insert the front support (20) on the axle housing. Tighten the bolt (19) to the requested torque.
  • Page 390 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES STEERING CYLINDER F27227 Disassembly Loosen the nut (1) with enough turns till it is protrud- ing over the threaded pin end of the tie rod (3). Beat on the nut (1) with an appropriate hammer in order to disjoin the tie rod (3) from the swivel hous- ing (2).
  • Page 391 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the tie rods (3) and (12) by loosing the nuts (4) and (11) with a suitable wrench, then check the conditions. Unscrew the fastening screws (6) and take the steering cylinder (7) out of its housing, if necessary use a rubber hammer.
  • Page 392 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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. F27233 Install the steering cylinder (7) already assembled on the central body.
  • Page 393 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Screw the locknuts (4) and (11) of the tie rods (3) and (12) only when the toe-in adjustment has been carried out. F27238...
  • Page 394 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES REDUCTION GEAR F27239 Disassembly Drain the oil completely from the planetary carrier. F27240...
  • Page 395 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Unscrew and remove both fastening screws (3) of the planetary carrier cover (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.
  • Page 396 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Position the planetary carrier cover (1) on a work- bench. Insert the thrust washers (6) and the gears (8) into the planetary carrier pins. Insert the needle bearings (7) into the gears (8). NOTE: grease well the needles.
  • Page 397 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES WHEEL HUB 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.
  • Page 398 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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). F27251 In order to extract the ring gear carrier from its hous- ing, screw in two of the just removed screws (5) in...
  • Page 399 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the wheel hub (11) using levers and a ham- mer to facilitate the operation. NOTE: collect the bearing (9). F27254 Position the wheel hub (11) on a flat surface and re- move the seal ring (13) with a lever.
  • Page 400 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the spacer (27) from the upper king pin housing. F27258 Position the swivel housing (14) on a flat surface and extract the seal ring (23) with a lever. NOTE: destructive operation for the seal ring (23). Turn the swivel housing and take the bush (22) out, using a suitable drift and a hammer.
  • Page 401 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the spacer (27) in the upper king pin housing. F27258 If the cone (15) of the spherical joint has been pre- viously removed, reassemble it to the lower king pin (16) using the special tool 380002662 under a press.
  • Page 402 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble both bearing cups (9) and (12) to their wheel hub (11) housings using the special tool 380002663 under a press or with a hammer. Insert the seal ring (13) into the wheel hub (11) with the special tool 380002227 and a hammer.
  • Page 403 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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 the special tool 380002223 and a hammer.
  • Page 404 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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.
  • Page 405 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES CARDAN SHAFTS F27272 Disassembly Remove the cardan shaft (6) from the axle shaft (1). F27273...
  • Page 406 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the seal rings (5) from the axle beam. NOTE: destructive operation for the seal rings (5). Remove the bush (4) from the axle beam only if the wear conditions require this. WARNING Be careful not to damage the bush seat.
  • Page 407 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the seal ring (5). WARNING Positioning the seal ring (5) as in figure. F27278 Insert the cardan shaft (6) into the axle shaft (1). WARNING Be careful not to damage the seal ring. F27273...
  • Page 408 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES DIFFERENTIAL SUPPORT 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). WARNING Support the differential support with a rope or other appropriate means.
  • Page 409 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Loosen and remove the screws (9) to take out the two ring nut retainers (8). F27284 Before removing the bolts, mark both half-collars (11) and the differential support with permanent ref- erence marks to avoid inverting them during re-as- sembly.
  • Page 410 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove differential unit (5). Remove the bearing (4) and (6) together with the dif- ferential assy. 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).
  • Page 411 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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;...
  • Page 412 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Once the adjustment of the pinion-ring gear back- lash has been carried out, check also that there is a minimum preloading on the differential box bear- ings. Repeat the whole sequence of the above mentioned operations till the indicated conditions are reached.
  • Page 413 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Once all the adjustment operations have been com- pleted, fit the ring nut retainers (8) and their screws (9), tightening them to the requested torque. F27298 Tighten the bolts (12) of both half collars (11) to the requested torque.
  • Page 414 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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 ->...
  • Page 415 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES DIFFERENTIAL GROUP Disassembly Use an extractor to remove bearing (12). F27306...
  • Page 416 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Use an extractor to remove bearing (2). F27307 Loosen all fastening screws (1) of the ring gear (11). WARNING This operation makes both differential half boxes free, so take care not to lower the inner compo- nents.
  • Page 417 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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 as- semble all inner components: the discs (4), the gears (5), the shaft (9), the gears (7), the spherical washers (6) and the pin (8).
  • Page 418 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Apply Loctite 242 on the thread of screws (1). F27316 Tighten the screws (1) to the specified torque. F27315 Press the bearing (12) or assemble after preheat- ing. F27317 Press the bearing (2). F27318...
  • Page 419 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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). F27320...
  • Page 420 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the ring nut (10) and collect its washer (9). F27321 Tap with a soft hammer to extract the pinion (1). WARNING Take care not to lower the pinion (1). Collect the washers (4) and (6), the spacer (5) and the bearing (8).
  • Page 421 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Check all pinion components for wear. WARNING The ring nut (10) and the spacer (5) must be re- placed when reassembling the unit. F27325 Assembly Place the differential support (7) on a workbench. Assemble the bearing cups (3) and (8).
  • Page 422 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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 differ- ential support seats.
  • Page 423 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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). 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...
  • Page 424 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Screw the ring nut (10) in, using the wrench 380002218 for ring nut and for pinion retainer. WARNING The torque setting is given by the preloading meas- urement on bearings; tighten the ring nut (10) grad- ually.
  • Page 425 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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.
  • Page 426 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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 be- tween the wheel hubs diameters ends is within the requested tolerance range.
  • Page 427 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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 adjust- ment and a long bar perfectly leaned over the ma- chined part of the central body (pinion side), so that the two bars form an acute angle at the maximum steering.
  • Page 428 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Steer completely towards the other side and repeat the same operation. F27348...

  • Page 429: Fault Finding

    Incorrect installation / defective axle Correct installation or repair or replace the differential in case it does not survive any one of the test phases. Overloading / incorrect weight distribution Remove excessive weight and redistribute load, following instructions related to the vehicle.
  • Page 430 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES PROBLEM CAUSE CORRECTION Ring gear tooth broken on the Excessive gear load compared to Replace bevel gear set. outer side the one foreseen Follow carefully the recommended Incorrect gear adjustment operations for the adjustment of the (excessive backlash) bevel gear set backlash.
  • Page 431 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Excessive wearing out of input Exhaustive use Replace the flange. flange spline Pinion nut loose Check that the pinion spline is not Pinion axle backlash excessively worn out. Replace bevel gear set if required. Fatigue failure of pinion teeth Exhaustive use Replace bevel gear set.

  • Page 432: Front Axle 4Ws "Carraro

    www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES FRONT AXLE 4WS “CARRARO” SPECIFICATIONS TYPE Front steering axle, model 26.28 F27378 POWERSHIFT SELF LOCKING RATIO • • 18.46...
  • Page 433 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES LUBRICATION AND GREASING Oil capacity 11.0 litres Oil specification: use recommended oil enriched in additives Akcela Nexplore MAT3525 Note: do not use synthetic or vegetable oil without consent of the axle manufacturer F27379 DESCRIPTION POSITION...
  • Page 434 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Before draining the oil from axle housing, use the breather (2) to release possible internal pressure. WARNING Risk of violent oil ejection. To drain the oil remove the level plug (1) and the drain plug (4).
  • Page 435 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Rotate the wheel end so that the hole (3) is in the po- sition shown in figure. Fill to the bottom of the fill plug hole with specified oil. Tighten the plug (3) to the requested torque.

  • Page 436: Disassembly And Assembly

    www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES DISASSEMBLY AND ASSEMBLY FRONT AND REAR SUPPORT F27380 Disassembly Remove the nut (3) and the bolt (2) and extract the flange (1). F27381...
  • Page 437 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the seal ring (13). F27382 Unscrew the screws (11) and remove the flange (12). F27383 Loosen the bolt (4). Take the rear support (5) out from the differential support. F27384 Remove the O-ring (7) from the rear support (5). NOTE: this is a destructive operation for the O-ring (7).
  • Page 438 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the bolt (4) and the lube nibble (9). Remove the bush (8) from the rear support (5). F27386 Remove the bushes (6) from the rear support (5). F27217 Remove the washer (10) from the differential sup- port only if necessary.
  • Page 439 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the O-ring (22). Remove the bolt (19) and the lube nibble (23). Remove the bush (18) from the front support (20). Remove the bushes (21) from front support (20). F27389 Remove the bush (17) and the washer (16) from the axle housing (15) only if necessary.
  • Page 440 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the bush (8) in the rear support (5). WARNING Align the bush hole with the bolt (4) hole. Mount the bolt (4). F27216 Lubricate with grease a new O-ring (7). Insert the O-ring (7) in the rear support (5). F27215 Insert the rear support (5) on the differential support.
  • Page 441 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Apply sealant on the bushes (21) contact surface. Assemble the bushes (21) to the front support (20) with a pad and a hammer. F27224 Assemble the bush (18) into the front support (20) with a suitable driver and a hammer.
  • Page 442 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the seal ring (13) use the special tool 380002225. 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. F27381...
  • Page 443 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES STEERING CYLINDER F27396 Disassembly Loosen the nut (1) with enough turns till it is protrud- ing 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).
  • Page 444 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the tie rods (3) and (10) by loosening the nuts (4) and (9) with a suitable wrench, then check their conditions. Unscrew the fastening screws (13) and take the steering cylinder (7). Remove only parts that need to be overhauled and/ or replaced.
  • Page 445 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the tie rods (3) and (8), the ball joints (3) and (10), the nuts (4) and (9) to the ends of the rod, then tighten with a dynamometric wrench to the re- quested torque.
  • Page 446 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Screw the locknuts (4) and (9) of the tie rods (3) and (10) only when the toe-in adjustment has been car- ried out. F29526...
  • Page 447 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES REDUCTION GEAR F27404 Disassembly Drain the oil completely from the planetary carrier. F27240...
  • Page 448 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Unscrew and remove both fastening screws (3) of the planetary carrier cover (1). F27241 Remove the planetary carrier cover (1) from the wheel hub. Position the planetary carrier cover (1) on a work- bench and check its wear conditions.
  • Page 449 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the planetary carrier cover (1) onto the wheel hub. F27405 Assemble the screws (3) and tighten to the specified torque. F27407 To up the oil on the wheel hub. Assemble the plug (2) onto the planetary carrier cover (1) and tighten to the specified torque.
  • Page 450 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES WHEEL HUB F27409 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.
  • Page 451 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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). F27251 In order to extract the ring gear carrier from its hous- ing, screw in two of the just removed screws (5) in...
  • Page 452 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the wheel hub (11) using levers and a ham- mer to facilitate the operation. NOTE: collect the bearing cone (9). F27254 Position the wheel hub (11) on a flat surface and re- move the seal ring (13) with a lever.
  • Page 453 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Collect the belleville washers (25) and (26). F27413 Position the swivel housing (14) on a flat surface and extract the seal ring (23) with a lever. NOTE: this is a destructive operation for the seal ring.
  • Page 454 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES If ball joints (15) and (27) have been previously re- moved, reassemble them on the lower (16) and up- per king pin (18). Grease carefully the seats of king pin (16) and (18) with specific grease.
  • Page 455 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the bearing (12) onto the swivel housing end (14). Assemble the wheel hub (11) on the swivel housing (14) and fit the bearing (9). 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 380002667.
  • Page 456 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Completely insert all bushes (6) using the special tool 380002667 and a hammer. Apply sealant on fastening bolts (5) thread. Assemble the screws (5) fastening the ring gear car- rier (7) and tighten to the specified torque. F27269 Insert a lever between the swivel housing (14) and the axle shaft and fit into the cardan shaft.
  • Page 457 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES CARDAN SHAFTS F27417 Disassembly Remove the cardan shaft (4) from the axle shaft (1). F27418...
  • Page 458 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the seal rings (3) from the axle beam (1). NOTE: destructive operation for the seal rings (3). Remove the bush (2) from the axle beam (1) only if the wear conditions require this. WARNING Be careful not to damage the bush seat.
  • Page 459 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES DIFFERENTIAL SUPPORT GROUP 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). WARNING Support the differential support with a rope or other appropriate means.
  • Page 460 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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 ref- erence marks to avoid inverting them during re-as- sembly.
  • Page 461 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove differential unit (5). Remove the bearing (4) and (6) together with the dif- ferential assy. 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).
  • Page 462 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the ring nuts (3) and (7) into the differen- tial 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;...
  • Page 463 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Once the adjustment of the pinion-ring gear back- lash has been carried out, check also that there is a minimum preloading on the differential box bear- ings. Repeat the whole sequence of the above mentioned operations till the indicated conditions are reached.
  • Page 464 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Once all the adjustment operations have been com- pleted, fit the ring nut retainers (8) and their screws (9), tightening them to the requested torque. F27298 Tighten the screws (12) of both half collars (11) to the specified torque.
  • Page 465 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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 ->...
  • Page 466 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES DIFFERENTIAL GROUP (STANDARD) F27437 Disassembly Use an extractor to remove bearing (10). F27438...
  • Page 467 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Use an extractor to remove bearing (2). F27307 Loosen all fastening screws (1) of the ring gear (11). WARNING This operation makes both differential half boxes free, so take care not to lower the inner compo- nents.
  • Page 468 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the gear (5) and the shim (4). F27440 Remove the shaft (8), the gears (7) and the spheri- cal washers (6). F27441 Remove the gear (12) and the shim (13). F27442 Assembly Apply a thin layer of Molicote G-n plus paste on the half housings of differential (3) and (9).
  • Page 469 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Apply a thin layer of Molicote G-n plus on the gears (5) and (12) and on the gears (7). F27444 Assemble the gear (12) and the shim (13). F27442 Position the shaft (8), the gears (7) and the spherical washers (6).
  • Page 470 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the two half housings of the differential unit (3) and (9). WARNING Carefully check that the marks of both differential half housings coincide. F27439 Assemble the ring gear (11) by means of a hammer. F27314 Apply Loctite 242 on the thread of screws (1).
  • Page 471 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Press the bearing (10) or assemble after preheat- ing. F29010 Press the bearing (2). F27318...
  • Page 472 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES DIFFERENTIAL GROUP (SELF-LOCKING) F27448 Disassembly Use an extractor to remove bearing (13). F27449...
  • Page 473 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Use an extractor to remove bearing (2). F27307 Loosen all fastening screws (1) of the ring gear (14). WARNING This operation makes both differential half boxes free, so take care not to lower the inner compo- nents.
  • Page 474 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the discs (4) and (5). F27452 Remove the sun gear (11). F27453 Remove the shaft (10), the gears (8) and the spher- ical washers (9). F27454 Remove the sun gear (7). F27455...
  • Page 475 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the discs (4) and (5). F27456 Assembly Apply a thin layer of Molicote G-n plus paste on the half housings of differential (3) and (12). WARNING Remove rests of dope. F27457 Apply a thin layer of Molicote G-n plus on the gears (7) and (11) and on the gears (8).
  • Page 476 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the gear (7). F27455 Position the shaft (10), the gears (8) and the spher- ical washers (9). F27454 Assemble the gear (11). F37839 Assemble discs (4) and (5). F27452...
  • Page 477 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Assemble the two half housings of the differential unit (3) and (12). WARNING Carefully check that the marks of both differential half housings coincide. F27451 Assemble the ring gear (14) by means of a hammer. F29320 Apply Loctite 242 on the thread of screws (1).
  • Page 478 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Press the bearing (13) or assemble after preheat- ing. F27460 Press the bearing (2). F27318...
  • Page 479 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES PINION GROUP 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). F27462...
  • Page 480 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Remove the ring nut (10) and collect its washer (9). F27463 Tap with a soft hammer to extract the pinion (1). WARNING Take care not to lower the pinion (1). Collect the washers (4) and (6), the spacer (5) and the bearing (8).
  • Page 481 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Check all pinion components for wear. WARNING The ring nut (10) and the spacer (5) must be re- placed when reassembling the unit. F27325 Assembly Place the differential support (7) on a workbench. Assemble the bearing cups (3) and (8).
  • Page 482 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Install “false differential box” special tools 380000407 + 380000440 to the differential group supports (7) and lock it with the half collar bolts. F28110 Assembly diagram of the “false differential box” tools on the bearing differential support seats. Use a depth gauge to measure distance “X”...
  • Page 483 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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). 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...
  • Page 484 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Screw the ring nut (10) in, using the wrench 380003218 for ring nut and for pinion retainer. WARNING The torque setting is given by the preloading meas- urement on bearings; tighten the ring nut (10) grad- ually.
  • Page 485 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES TOE-IN / STEERING ANGLE F28113 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. 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;...
  • Page 486 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES 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 be- tween the wheel hubs diameters ends is within the requested tolerance range.
  • Page 487 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES After adjusting, screw in the locknuts (2) of the guide rods (1) to the prescribed tightening torque. F27344 Steering angle adjustment Use the same bars assembled for the toe-in adjust- ment and a long bar perfectly leaned over the ma- chined part of the central body (pinion side), so that the two bars form an acute angle at the maximum steering.
  • Page 488 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Steer completely towards the other side and repeat the same operation. F27348...
  • Page 489 Incorrect installation / defective axle Correct installation or repair or replace the differential in case it does not survive any one of the test phases. Overloading / incorrect weight distribution Remove excessive weight and redistribute load, following instructions related to the vehicle.
  • Page 490 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES PROBLEM CAUSE CORRECTION Ring gear tooth broken on the Excessive gear load compared to Replace bevel gear set. outer side the one foreseen Follow carefully the recommended Incorrect gear adjustment operations for the adjustment of the (excessive backlash) bevel gear set backlash.
  • Page 491 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES Fatigue failure of pinion teeth Exhaustive use Replace bevel gear set. See if the fracture line is well Continuous overload defined (wave lines, beach lines) Pinion and ring teeth breakage Crash load of differential Check and/or replace other components differential components.
  • Page 492 www.maskinisten.net Copyright © SECTION 25 - FRONT AXLES SPECIAL TOOLS P/N CNH 380000406 Disassembly/assembly of differential ring nuts • • 380000407 + Calculation of pinion shims • • 380000440 380002213 Assembly of seal ring in the wheel hub • 380002218 Disassembly/assembly of pinion rings •...
  • Page 493 Copyright © 580SR 580SR+ 590SR 695SR SECTION 27 - REAR AXLE 1. REAR AXLE 2WS ............................3 1.1 DESCRIPTION AND OPERATION....................... 3 1.2 SPECIFICATIONS ..........................6 1.3 DISASSEMBLY AND ASSEMBLY......................8 1.4 FAULT FINDING..........................27 2. REAR AXLE 4WS “CARRARO”........................28 2.1 SPECIFICATIONS ..........................
  • Page 494 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE...

  • Page 495: Rear Axle 2Ws

    www.maskinisten.net Copyright © SECTION 27 - REAR AXLE REAR AXLE 2WS DESCRIPTION AND OPERATION 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;...
  • Page 496 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE ELECTRICAL DIFFERENTIAL LOCKING OPERATION (Powershift) WARNING The differential lock fitted to this machine is operated by oil pressure and controlled by an electrically op- erated solenoid. The solenoid valve is energized by means of the button (1) mounted in the right control lever.
  • Page 497 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE MECHANICAL DIFFERENTIAL LOCKING OPERATION (Powershuttle) WARNING 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 turn- ing: this could cause accidents. In conditions inducing wheel slip, hold down the dif- ferential lock pedal (1) with your heel until the lock is felt to engage.

  • Page 498: Specifications

    www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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)
  • Page 499 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE MOUNTING SCREW TORQUE F29551 1. Screw of half shaft: 554÷626 Nm 7. Screw of baffle oil: 43÷51 Nm 2. Screw of axle assy - rear RH or LH: 190÷231 Nm 8. Plug: 27÷34 Nm 3.

  • Page 500: Disassembly And Assembly

    www.maskinisten.net Copyright © SECTION 27 - REAR AXLE DISASSEMBLY AND ASSEMBLY 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 li- tres and drain the oil from the plug at the base of the axle.
  • Page 501 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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). F29552 Remove the left housing of the half-beam (2) with the differential (3) using the tool 380000990, from...
  • Page 502 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE DIFFERENTIAL DISASSEMBLY 1. Safety ring 9. Bearing 2. Washer 10. Thrust washer 3. Dog gear 11. Side gear 4. Spring 12. Spider assembly 5. Dog 13. Side gear 6. Differential half housing 14.
  • Page 503 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE The differential lock can be disassembled by com- pressing the spring and carefully detaching the snap ring (1). With the snap ring removed disassemble the: wash- er (2), outer dog (3), spring (4), inner dog (5) from the housing (6).
  • Page 504 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE PINION REMOVAL 1. Ring nut 9. Disc 2. Lock pin 10. Seal 3. Washer 11. Bearing 4. Seal 12. Pinion 5. Coupling 13. Bearing 6. Bearing 14. Safety ring 7. Spacer 15. Screw 8.
  • Page 505 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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 gas- ket (4). Remove the coupling (5). Loosen and remove the screws (15).
  • Page 506 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Remove the snap ring (14) from the axle inner cen- tral body. Using an rubber hammer, take out the pinion (12). F29553 Remove from the pinion (12), the spacer (7) and by means of extractors, the bearings (11) and (13).
  • Page 507 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE BRAKE GROUP DISASSEMBLY Powershuttle F29554 Powershift F29555 1. Housing brake outer 11. Block (powershuttle) 2. O-ring 12. Washer 3. O-ring 13. Screw 4. Piston brake 14. Screw 5. Disc brake intermediate 15. Housing brake inner 6.
  • Page 508 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Unscrew and remove the screws (17) then disas- semble the block (11) with the shims (10). F29556 Loosen and remove the screws (9). Remove the housing brake inner (7). Remove the brake pads (6) and the intermediate disks (5).
  • Page 509 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE AXLE SHAFT ASSY RIGHT AND LEFT DISASSEMBLY 1. Sun gear 9. Screw 2. Retainer 10. Screw bleeder 3. Screw 11. O-ring 4. Washer 12. Axle housing assy right or left 5. Shim 13.
  • Page 510 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Remove the sun gear (1). 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).
  • Page 511 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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.
  • Page 512 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Reassembly of the bearing is the reverse proce- dure. 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).
  • Page 513 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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 fabri- cated spanner 380002675 to the flange (1) and torque to 406 Nm with spanner to the locknut (2).
  • Page 514 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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 554÷626 Nm; Z by means of a dial gauge, find out the axle back- lash (for instance 0.562 mm);...
  • Page 515 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE MEASURING OF AXLE SHAFT ROLLING TORQUE After fitting the correct shim to set the preload: man- ufacture 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 re- sistance which should be 2.3 - 10 Nm.
  • Page 516 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE DIFFERENTIAL BEARING PRELOAD This adjustment is made by shimming the right hand differential bearing cone. The value of following shimming is required: dimen- sion “T”. VALUE “T” SHIMS 0.034 ÷ 0.039 81803515 0.040 ÷...
  • Page 517 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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 pro- vide design gap of 0.10 - 0.20 mm. VALUE “S”...
  • Page 518 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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).

  • Page 519: Fault Finding

    www.maskinisten.net Copyright © SECTION 27 - REAR AXLE FAULT FINDING PROBLEM CAUSE CORRECTION Differential lock not engaging External linkage damaged or Replace/repair as required. (mechanical differential lock) broken Internal linkage, cross shaft rod, Remove and inspect. fork or pivot shaft damaged/ broken Damaged or broken teeth on Remove differential and inspect...

  • Page 520: Rear Axle 4Ws "Carraro

    www.maskinisten.net Copyright © SECTION 27 - REAR AXLE REAR AXLE 4WS “CARRARO” SPECIFICATIONS Rear steering axle, model 26.32M POWERSHIFT SELF LOCKING RATIO • • 19,038...
  • Page 521 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE LUBRICATION AND GREASING Differential oil capacity 11 litres Reduction gear oil capacity, on each side 1.3 litres Oil specification: use recommended oil enriched in additives Akcela Nexplore MAT3525 Note: do not use synthetic or vegetable oil without consent of the axle manufacturer DESCRIPTION POSITION...
  • Page 522 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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).
  • Page 523 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Before draining the oil, loosen the breather (6) to re- lease possible internal pressure. Check oil level and top up if necessary. Tighten the plug with a torque wrench to the pre- scribed torque.

  • Page 524: Disassembly And Assembly

    www.maskinisten.net Copyright © SECTION 27 - REAR AXLE DISASSEMBLY AND ASSEMBLY FRONT FLANGE F28010 Disassembly Remove the snap ring (1). F28011...
  • Page 525 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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). F29009 Assembly Assemble the washer (7) and the new O-ring (6). F29322 Assemble the gasket (5).
  • Page 526 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Assemble the new O-ring (4) and the seal ring (3). F29324 Assemble the front flange (2). F28012 Assemble the snap ring (1). F28011...
  • Page 527 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE STEERING CYLINDER F28013 Disassembly Loosen the nut (1) with enough turns till it is protrud- ing 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).
  • Page 528 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Remove the tie rods (3) and (13) by loosening the nuts (4) and (12) with a suitable wrench, then check their conditions. Unscrew the fastening screws (6) and (9) and take the steering cylinder (7) out of its housing, if neces- sary use a rubber hammer.
  • Page 529 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Install the steering cylinder (7) already assembled on the central body. Assemble and tighten the screws (6) and (9) to the specified torque. Align the swivel housing (14) with the axle. Screw in the tie rod (13) so that its ball joint can be inserted into the swivel housing arm (14).
  • Page 530 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE REDUCTION GEAR F27404 Disassembly Drain the oil completely from the planetary carrier. F27240...
  • Page 531 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Unscrew and remove both fastening screws (3) of the planetary carrier cover (1). F28044 Remove the planetary carrier cover (1) from the wheel hub. Position the planetary carrier cover (1) on a work- bench and check its wear conditions.
  • Page 532 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE If the pins of the gears are in poor conditions, re- place 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). F28024 Insert all the rollers into the gears, then position the two washers (8) and (9).
  • Page 533 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Assemble the planetary carrier cover (1) onto the wheel hub. F27405 Assemble the screws (3) and tighten to the specified torque. F28044 To up the oil on the wheel hub. Assemble the plug (2) onto the planetary carrier cover (1) and tighten to the specified torque.
  • Page 534 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE WHEEL HUB 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.
  • Page 535 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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). F27251 To extract the ring gear carrier, screw in two of the just removed screws (5) into the threaded holes.
  • Page 536 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Remove the O-ring (15). Remove the wheel hub (11) using levers and a ham- mer to facilitate the operation. NOTE: collect the bearing cone (9). F27254 Position the wheel hub (11) on a flat surface and re- move the seal ring (13) with a lever.
  • Page 537 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Collect the belleville washers (23) and (28). F28046 Position the swivel housing (14) on a flat surface and extract the seal ring (22) with a lever. NOTE: this is a destructive operation for the seal ring.
  • Page 538 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Grease well the king pin housings with specific grease. Position the belleville washers (23) and (29). F28046 If previously removed, assemble the king pins (24) and (27) onto the king pins (16) and (18). F28027 Secure the swivel housing (14) with a belt or a rope to a hoist or to any other supporting device.
  • Page 539 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Position the wheel hub (11) on a workbench and as- semble 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) with the special tool 380002213 and a hammer.
  • Page 540 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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 Completely insert all bushes (6) using the special tool 380002667 and a hammer.
  • Page 541 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE CARDAN SHAFTS F27279 Disassembly Remove the cardan shaft (1) from the axle shaft (4). F27280...
  • Page 542 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Remove the seal rings (2) from the axle beam (4). NOTE: destructive operation for the seal rings (3). Remove the bushing (3) from the axle shaft (4) only if the wear conditions require it. WARNING Be careful not to damage the bush seat.
  • Page 543 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE AXLE BODY AND BRAKES F28030 Disassembly Put alignment marks on the axle beam body and on the differential supporting flanges, in order to identi- fy the right side and the left side with certainty. F28031...
  • Page 544 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Position the axle on supports fitted to hold either the central body or the axle-beam, even after their dis- junction, 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).
  • Page 545 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Remove the O-ring (4) and (19) from its housing and from oil pipe hole and check its conditions. F28037 Collect the brake flange (7) and place it on a work- bench or fix it in a clamp. Unscrew screws (11).
  • Page 546 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Take the piston out (14). If necessary, blow in air through the brake bleeder vent to eject the piston, using the minimum pres- sure. Remove the O-rings (16) and (17) from the piston (14) and check their conditions.
  • Page 547 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Assemble the new O-rings (4) and (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 counter- disc (15).
  • Page 548 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Assemble the axle-beam (1) on the flange, being careful to the fastening holes’ alignment. WARNING 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.
  • Page 549 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE DIFFERENTIAL GROUP (STANDARD) F28050 Disassembly Loosen the screw (4) and remove the ring nut retain- er (5). Unscrew the ring nut with suitable special tool 320002218. Remove the ring nut (6). F28051...
  • Page 550 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Remove the bearing cups (6). F28052 Support the differential assy (2) with a rod and re- move it. F28053 Use an extractor to remove bearing (18). F28054 Use an extractor to remove bearing (7). F28055...
  • Page 551 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Loosen all screws (1) of the ring gear (10). WARNING This operation makes both differential half boxes free, so take care not to lower the inner compo- nents. F28056 Remove the ring gear (10) by means of a hammer. F28057 Check the marking points (8) and (9) that will be useful during the assemblage.
  • Page 552 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Remove the shaft (13), the gears (14) and the spherical washers (15). F28060 Remove the gear (12) and the shim (11). F28061 Assembly Apply a thin layer of Molicote G-n plus paste on the half housings of differential (8) and (9).
  • Page 553 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Assemble the gear (16) and the shim (17). F28064 Position the shaft (13), the gears (14) and the spher- ical washers (15). F28060 Assemble the gear (12) and the shim (11). F28066 Assemble the two half housings of the differential unit (8) and (9).
  • Page 554 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Assemble the ring gear (10) by means of a hammer. F28067 Apply Loctite 242 on the thread of screws (1). F27316 Tighten the screws (1) to the specified torque. F27315 Press the bearing (18) or assemble after preheat- ing.
  • Page 555 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Press the bearing (7). F28069 Support the differential assy (2) with a rod and as- semble it. F28070 Fit the outer cups of the bearings (7) by means of the special tool 380002671 and a hammer. F28071 Insert and tighten the ring nuts (6), using the wrench 380002218 until the clearance of the bearings is re-...
  • Page 556 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE DIFFERENTIAL GROUP (SELF-LOCKING) F28073 Disassembly Loosen the screw (4) and remove the ring nut retain- er (5). Unscrew the ring nut with suitable special tool 380002218. Remove the ring nut (6). F28051...
  • Page 557 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Remove the bearing cups (6) with a hammer. F28052 Support the differential assy (2) with a rod and re- move it. F28053 Use an extractor to remove bearing (18). F28054 Use an extractor to remove bearing (7). F28055...
  • Page 558 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Loosen all screws (1) of the ring gear (10). WARNING This operation makes both differential half boxes free, so take care not to lower the inner compo- nents. F28056 Remove the ring gear (10) by means of a hammer. F28057 Check the marking points (8) and (9) that will be useful during the assemblage.
  • Page 559 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Remove the gear (19) and the shim (13). F28075 Remove the shaft (17), the gears (16) and the spherical washers (15). F28076 Remove the gear (14) and the shim (13). F28077 Assemble the discs (11) and (12). 11 12 F28078...
  • Page 560 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Assembly Apply a thin layer of Molicote G-n plus paste on the half housings of differential (8) and (9). WARNING Remove rests of dope. F28079 Apply a thin layer of Molicote G-n plus on the gears (14) and (19) and on the gears (16).
  • Page 561 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Position the shaft (17), the gears (16) and the spher- ical washers (15). F28082 Assemble the gear (19) and the shim (13). F28081 Assemble discs (11) and (12). 11 12 F28074 Assemble the two half housings of the differential unit (8) and (9).
  • Page 562 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Assemble the ring gear (10) by means of a hammer. F28067 Apply Loctite 242 on the thread of screws (1). F27316 Tighten the screws (1) to the specified torque. F27315 Press the bearing (18) or assemble after preheat- ing.
  • Page 563 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Press the bearing (7). F28069 Support the differential assy (2) with a rod and as- semble it. F28070 Fit the outer cups of the bearings (7) by means of the special tool 380002671 and a hammer. F28071 Insert and tighten the ring nuts (6), using the wrench 380002218 until the clearance of the bearings is re-...
  • Page 564 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE PINION GROUP F28083 Disassembly In order to prevent serious damage to the pinion thread, unscrew the ring nut (9) with the special tool 380000406. F29645...
  • Page 565 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Once the ring nut washer has been removed, ex- tract 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).
  • Page 566 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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 us- ing the special tool 380002215 for outer bearing race and for inner bearing race.
  • Page 567 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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. F28093 Carry out the measurement with a depth gauge through the suitable false pinion hole.
  • Page 568 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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. F28096 Insert the shims (4) and (6) and the spacer (5) into the pinion (1).
  • Page 569 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Carry out the preloading measurement (P) of the pinion taper roller bearings, using a dynamometer 380002672. The adjustment is carried out by increasing the ring nut torque gradually, being careful not to exceed. Once you got the requested preloading value, caulk the ring nut.
  • Page 570 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE 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. 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;...
  • Page 571 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Check that the difference of the measurements be- tween the wheel hubs diameters ends is within the requested tolerance range. The nominal toe-in value (A) is referred to the exter- nal diameter of the wheel hubs flange, therefore the measured value (M) at the bars ends must be relat- ed to the ratio between length of the bar and flange diameter...
  • Page 572 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Steering angle Use the same bars assembled for the toe-in adjust- ment and a long bar perfectly leaned over the ma- chined part of the central body (pinion side), so that the two bars form an acute angle at the maximum steering.

  • Page 573: Fault Finding

    Incorrect installation / defective axle Correct installation or repair or replace the differential in case it does not survive any one of the test phases. Overloading / incorrect weight distribution Remove excessive weight and redistribute load, following instructions related to the vehicle.
  • Page 574 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE PROBLEM CAUSE CORRECTION Ring gear tooth broken on the Excessive gear load compared to Replace bevel gear set. outer side the one foreseen Follow carefully the recommended Incorrect gear adjustment operations for the adjustment of the (excessive backlash) bevel gear set backlash.
  • Page 575 www.maskinisten.net Copyright © SECTION 27 - REAR AXLE Fatigue failure of pinion teeth Exhaustive use Replace bevel gear set. See if the fracture line is well Continuous overload defined (wave lines, beach lines) Pinion and ring teeth breakage Crash load of differential Check and/or replace other components differential components.

  • Page 576: Special Tools

    www.maskinisten.net Copyright © SECTION 27 - REAR AXLE SPECIAL TOOLS P/N CNH APPLICATION 380000406 Disassembly/Assembly of differential ring nuts • 380000816 Planetary carrier disassembly • 380000986 + Disassembly bearing cups from the axle housing • 380000987 380000990 Axle housing lifting •...
  • Page 577 Copyright © 580SR 580SR+ 590SR 695SR 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...
  • Page 578 www.maskinisten.net Copyright © SECTION 33 - BRAKES SYSTEM...

  • Page 579: Specifications

    www.maskinisten.net Copyright © SECTION 33 - BRAKES SYSTEM SPECIFICATIONS BRAKES OPERATION HYDRAULIC Brakes Wet disc, piston operated Oil brake Akcela LHM Number discs (on side) Brakes disc total friction area 1,440 cm BRAKES OPERATION HYDRAULIC Brakes Wet disc, piston operated Oil brake Akcela LHM Number discs (on side)
  • Page 580 www.maskinisten.net Copyright © SECTION 33 - BRAKES SYSTEM BRAKE SYSTEM LAYOUT (2WS) 1. Brake piston assembly 5. Master cylinders 2. Brake discs 6. Parking brake 3. Brake tank 7. Axle shaft 4. Pressure switch...
  • Page 581 www.maskinisten.net Copyright © SECTION 33 - BRAKES SYSTEM BRAKE SYSTEM LAYOUT (4WS) 1. Brake piston assembly 5. Master cylinders 2. Brake discs 6. Parking brake 3. Brake tank 7. Axle shaft 4. Pressure switch...

  • Page 582: Parking Brake

    www.maskinisten.net Copyright © SECTION 33 - BRAKES SYSTEM PARKING BRAKE The parking brake is fitted to all models and incorpo- rates 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.

  • Page 583: Parking Brake Adjustment

    www.maskinisten.net Copyright © SECTION 33 - BRAKES SYSTEM PARKING BRAKE ADJUSTMENT The parking brake is located on the transmission out- put 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), park- ing brake caliper (4).

  • Page 584: Brake Cylinders

    www.maskinisten.net Copyright © SECTION 33 - BRAKES SYSTEM BRAKE CYLINDERS Brake cylinders are accessible from the engine com- partment. The brake cylinders are linked by a balancing pipe (12) situated below the cylinders to maintain equal oil pressure between the two cylinders. 1.
  • Page 585 www.maskinisten.net Copyright © SECTION 33 - BRAKES SYSTEM MASTER CYLINDER WITH BRAKES RELEASED F29371 Trapped oil Tank oil (no pressure) 1. Oil to cylinder (right hand side) 6. Cylinder body 2. Pressure switch 7. Cylinder body 3. Secondary spool 8. Primary spool stop 4.
  • Page 586 www.maskinisten.net Copyright © SECTION 33 - BRAKES SYSTEM CYLINDER WITH BRAKE PEDALS DEPRESSED F29372 Pressurized brake oil Tank oil (no pressure) 1. Oil to cylinder (right hand side) 6. Cylinder body 2. Pressure switch 7. Cylinder body 3. Secondary spool 8.
  • Page 587 www.maskinisten.net Copyright © SECTION 33 - BRAKES SYSTEM CYLINDER WITH ONE BRAKE PEDAL DEPRESSED F29373 Pressurized brake oil Tank oil (no pressure) 1. Oil to cylinder (right hand side) 6. Cylinder body 2. Pressure switch 7. Cylinder body 3. Secondary spool 8.
  • Page 588 www.maskinisten.net Copyright © SECTION 33 - BRAKES SYSTEM 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.

  • Page 589: Oil Brake Tank

    www.maskinisten.net Copyright © SECTION 33 - BRAKES SYSTEM 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;...
  • Page 590 www.maskinisten.net Copyright © SECTION 33 - BRAKES SYSTEM NOTES:...
  • Page 591 Copyright © 580SR 580SR+ 590SR 695SR 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 1.3 HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS..........7 1.4 HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS ..............
  • Page 592 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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..........................

  • Page 593: Hydraulic Diagrams

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC DIAGRAMS HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS...
  • Page 594 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 1. Front axle 2. Steering control valve 3. 4x1 bucket cylinders 4. Dipper cylinders 5. Boom cylinders 6. Ride control valve (optional) 7. Ride control accumulator (optional) 8. Loader attachment control valve 9.

  • Page 595: Hydraulic Diagram - 2Ws Sideshift Pilot Models

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS...
  • Page 596 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 1. Front axle 2. Steering control valve 3. 4x1 bucket cylinders 4. Dipper cylinders 5. Boom cylinders 6. Ride control valve (optional) 7. Ride control accumulator (optional) 8. Loader attachment control valve 9.

  • Page 597: Hydraulic Diagram - 4Ws Sideshift Mechanical Models

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS...
  • Page 598 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 1. Front axle 2. Steering control valve 3. 4x1 bucket cylinders 4. Dipper cylinders 5. Boom cylinders 6. Ride control valve (optional) 7. Ride control accumulator (optional) 8. Loader attachment control valve 9.

  • Page 599: Hydraulic Diagram - 4Ws Sideshift Pilot Models

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS...
  • Page 600 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 1. Front axle 2. Steering control valve 3. 4x1 bucket cylinders 4. Dipper cylinders 5. Boom cylinders 6. Ride control valve (optional) 7. Ride control accumulator (optional) 8. Loader attachment control valve 9.

  • Page 601: Hydraulic Diagram - 4Ws Center Pivot Pilot Models

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS...
  • Page 602 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 1. Front axle 2. Steering control valve 3. 4x1 bucket cylinders 4. Dipper cylinders 5. Boom cylinders 6. Ride control valve (optional) 7. Ride control accumulator (optional) 8. Loader attachment control valve 9.

  • Page 603: Hydraulic Pump

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC PUMP DESCRIPTION AND OPERATION 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.
  • Page 604 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM PUMP (110 HP ENGINE) 1st PUMP 2nd PUMP Direction of rotation (looking on drive shaft) Clockwise (D) Displacement 40.258 (cm /rev) 35.427 (cm /rev) Inlet pressure range for pump 0.7 - 3 bar Maximum continuous pressure 260 bar 260 bar...
  • Page 605 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM MOUNTING SCREW TORQUE HYDRAULIC DIAGRAM...

  • Page 606: Load Sensing Valve

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM LOAD SENSING VALVE 1. Orifice 8. Steering relief valve 2. Rear systems (EF) 9. Relief valve adjuster 3. Filter 10. Poppet 4. Spool 11. Return to inlet pump port 5. To steering priority flow (CF) 12.
  • Page 607 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM F29457 Load sensing valve with pump running - Steering in neutral Return to oil tank Trapped oil Pressure oil 1. Orifice 5. To steering priority flow (CF) 2. Rear systems (EF) 6. Orifice 3.

  • Page 608: Removal

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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.

  • Page 609: Components

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM COMPONENTS 1. Screw 19. Bushing 2. Steering control valve 20. Gasket 3. Spool 21. Bushing 4. O-ring 22. Elastic retainer 5. Plug 23. Bearing 6. Valve 24. Gear 7. Filter 25. Gear 8.

  • Page 610: Disassembly And Assembly

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY AND ASSEMBLY 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).
  • Page 611 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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”...
  • Page 612 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Inspect the wear track cut by the gears in pump body. The body can be reused if the track is bright and polished and does not exceed 0.08 - 0.076 mm in depth. Examine bearing block faces for scoring and flat- ness paying particular attention to the face which abuts the gears.
  • Page 613 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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.

  • Page 614: Control Valves

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM CONTROL VALVES CONTROL VALVES “REXROTH” (MECHANICAL MODELS) The hydraulic circuit is a load sensing flow sharing Loader attachment control valve system working in conjunction with a fixed displace- The loader control valve is mounted on the right ment gear type hydraulic pump.
  • Page 615 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Hydraulic system oil Steering system oil Load sensing oil Suction oil Return to oil tank 1. Hydraulic tank 8. Backhoe hammer control valve 2. Hydraulic pump 9. Backhoe hammer 3. Power steering 10.
  • Page 616 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 com- pensator.
  • Page 617 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM F29288 Load sensing flow sharing - All spools in neutral Pump pressure Trapped oil Return to oil tank 1. Load non-return check valve 2. Load sense line 3. Pressure compensator 4. Spool...
  • Page 618 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM One hydraulic circuit operating When a single hydraulic circuit is operated the spool erate the flow balancer valve and pump pressure in- in the control valve section is moved allowing oil to crease accordingly.
  • Page 619 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM F29290 Load sensing flow sharing - One spool operating Pump pressure Trapped oil Return to oil tank 1. Load non-return check valve 3. Pressure compensator 2. Load sense line 4. Spool...
  • Page 620 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Two or more hydraulic circuits operating When two or more hydraulic systems operate, each operating pressure to be sensed in the load sensing system will operate at a different pressure. gallery. If pump flow to a specific system is not controlled, Pump pressure will rise until it exceeds the pressure the system requiring a lower operating pressure will of the check valve of the system operating at the...
  • Page 621 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM F29292 Load sensing flow sharing - Two spools operating spool operating pressure spool operating pressure Trapped oil Return to oil tank 1. Load non-return check valve 3. Pressure compensator 2. Load sense line 4.
  • Page 622 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM LOADER CONTROL VALVE The loader control valve is mounted on the right side of the machine adjacent to the pump. The valve as- sembly consists of two or three spool operated sec- tions: Z Loader lifting Z Loader bucket...
  • Page 623 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 oper- ating positions.
  • Page 624 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 sec- tions together with an inlet and outlet end cover. Valve sections are: Z Right-hand stabilizer Z Stabilizer left...
  • Page 625 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Removal Z Position the loader backhoe on a hard level sur- face. 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.
  • Page 626 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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).
  • Page 627 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Disassembly of control valve sections (with me- chanical control) There are indicated all possible solutions relevant to backhoe control sections with mechanical control. 1. Secondary relief valve 6. Spool with mechanical detent system (loader 2.
  • Page 628 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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).
  • Page 629 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 out- side of the spool.

  • Page 630: Rexroth" Control Valves (Pilot Models)

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM “REXROTH” CONTROL VALVES (PILOT MODELS) The loader backhoe with hydraulic control (pilot mod- els) differs basically from the mechanical loader backhoe models for the reason that the controls driv- ing the loader attachment and the stabilizers are hy- draulic instead of being mechanical.
  • Page 631 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Hydraulic system oil Suction oil Steering system oil Return to oil tank Load sensing oil Control circuit oil 1. Hydraulic tank 10. Oil cooler 2. Pump 11. Return line distributor block 3. Power steering 12.
  • Page 632 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM LOADER CONTROL VALVE The loader control valve is mounted on the right side of the machine adjacent to the pump. The valve as- sembly consists of two or three spool operated sec- tions: Z Loader lifting Z Loader bucket...
  • Page 633 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 mov- ing the relevant control levers through all operating positions.
  • Page 634 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 sec- tions together with an inlet and outlet end cover. Valve sections are: Z Right-hand stabilizer Z Stabilizer left...
  • Page 635 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 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 oper-...
  • Page 636 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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).
  • Page 637 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Disassembly of control valve sections (with hy- draulic control) In this section are indicated all possible solutions rel- evant to backhoe control valve sections with hydrau- lic control. 1. Secondary relief valve 3.
  • Page 638 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 sec- tion.

  • Page 639: Solenoid Valve For Piloting The Backhoe Control Valve (With Hydraulic Control)

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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...
  • Page 640 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM If the loader backhoe is equipped with a telescopic dipper and if the rear control valve contains an aux- iliary section, the solenoid valve consists of valve (B) and module (C). Removal Z Position the loader backhoe on a hard level sur- face.
  • Page 641 Loosen and remove the three screws (3) and disas- semble valve (4). Check and eventually replace the O-rings (5). In case of necessity it is possible to disassemble the Check and eventually replace the O-rings (10). various solenoid valves from the manifold blocks.

  • Page 642: Relief Valves

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM RELIEF VALVES The relief valves may be operated with anti-cavita- tion feature (1) or direct acting (2) and protect indi- vidual circuits from excessive pressure. The backhoes, having this kind of control valves in- stalled, are equipped with different relief valves.
  • Page 643 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Circuit relief valves operating Relief valve inoperative When the system is not subject to overload condi- tions pressure in the system is insufficient to over- come pilot valve spring pressure and move the valve of its seat.
  • Page 644 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Anti-cavitation operation Circuit relief valves with an anti-cavitation feature are fitted in circuits where rapid extension of the cyl- inder could create a void condition and permit the transfer of oil from the high pressure side of a cylin- der to the lower pressure (void) end of the cylinder.
  • Page 645 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Pilot-operated pressure relief valve with anti-cavita- tion feature subjected to overload and fully relieving high-pressure oil 1. Sleeve 2. Poppet valve 3. Pilot valve 4. Pilot valve body 5. Piston 6. Control valve (cylinder) exhaust gallery 7.
  • Page 646 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 tele- scopic dipper controls through all operating posi- tions.
  • Page 647 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Direct acting circuit relief valve 1. Body 6. Cover 2. Poppet 7. O-ring 3. Spring 8. Nut 4. Spring 9. O-ring 5. Shim 10. Adjuster screw Loader bucket relief valve 1. Relief valve assembly 2.
  • Page 648 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM System pressure relief valve adjustment After overhaul, the pressure relief valves of the sys- tem must be tested and adjusted using a suitable hand pump (1), a 275 bar pressure gauge and a V.
  • Page 649 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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.

  • Page 650: Accumulator "Glide Ride" Parker

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 in- tervals afterwards based on this initial experience.
  • Page 651 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 accumulator’s gas valve, allowing the precharge pressure to be checked or reduced.
  • Page 652 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 p is Correct Z Screw the handwheel (A) counterclockwise to close the accumulator gas valve.

  • Page 653: Hydraulic Swing System

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC SWING SYSTEM DESCRIPTION AND OPERATION 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.

  • Page 654: Hydraulic Oil Flow

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC OIL FLOW Hydraulic feed to the swing cylinders is controlled by If the swing control valve is suddenly returned to the swing section of the backhoe attachment control neutral mid-way through a full power swing the sup- valve, which contains pilot-operated pressure relief ply and exhaust ports in the main control valve are valves with anti-cavitation feature to protect the sys-...
  • Page 655 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM F29480 Pump pressure oil 1st stage restricted return oil 2nd stage restricted return oil Return to oil tank 1. Control valve swing section 2. One way restrictor 3. Cushioning rod 4. Right hand cylinder 5.

  • Page 656: Hydraulic Cylinders

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC CYLINDERS 1. Loader attachment boom cylinder 2. Loader bucket cylinder 3. 4x1 loader bucket cylinder 4. Backhoe boom cylinder 5. Backhoe dipper cylinder 6. Backhoe bucket cylinder 7. Telescopic cylinder 8. Swing backhoe cylinder 9.

  • Page 657: Loader Attachment Boom Cylinder

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM LOADER ATTACHMENT BOOM CYLINDER (1) Stroke (2) Completely retracted (1) Stroke (2) Completely retracted...
  • Page 658 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM CYLINDER REMOVAL Park machine on a flat surface. Raise the loader suf- ficiently to allow the loader cylinder pin to be re- moved. Remove the loader bucket and support the arm us- ing a suitable stand or hoist.
  • Page 659 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Remove the ring (3) and the pin (4). Use a hammer to extract the rod pin (5). Remove the loader attachment boom cylinder.
  • Page 660 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY CYLINDER 1. Cylinder rod 9. Back-up ring 2. Bushing 10. O-ring 3. Wiper ring 11. Piston 4. Ring seal 12. Piston gasket 5. Ring seal 13. Piston guide 6. Guide bush 14.
  • Page 661 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 bar- rel (15) using a plastic hammer.

  • Page 662: Loader Bucket Cylinder

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM LOADER BUCKET CYLINDER (1) Stroke (2) Completely retracted (1) Stroke (2) Completely retracted...
  • Page 663 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM CYLINDER REMOVAL Park machine on a flat surface and position the bucket firmly on the ground. Relieve the residual pressure in the system by mov- ing the loader control lever through all operating po- sitions.
  • Page 664 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY CYLINDER 1. Bushing 9. O-ring 2. Cylinder rod 10. Piston 3. Wiper ring 11. Piston gasket 4. Ring seal 12. Piston guide 5. Ring seal 13. Screw 6. Cylinder head 14. Cylinder tube 7.
  • Page 665 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Support the cylinder rod (2) and use the wrench 380000722 to loosen the cylinder head (6). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture. Remove the stop ring (7) Extract the cylinder head (6) from the cylinder barrel (14) by tapping it with a plastic hammer.

  • Page 666: 4X1 Loader Bucket Cylinder

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 4X1 LOADER BUCKET CYLINDER 1. Cylinder rod pin 5. Dowel 2. Dowel 6. Nut 3. Bucket 7. Cylinder bottom pin 4. Cylinder CYLINDER REMOVAL Park machine on a flat surface and position the bucket firmly on the ground.
  • Page 667 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Disconnect the hydraulic hoses. 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.
  • Page 668 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY CYLINDER 1. Cylinder tube 7. Cylinder head 2. Piston 8. Gasket 3. Pin 9. Wiper ring 4. O-ring 10. Cylinder rod 5. Piston guide 11. Bushing 6. O-ring...

  • Page 669: Backhoe Boom Cylinder

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM BACKHOE BOOM CYLINDER (1) Stroke (2) Completely retracted CYLINDER REMOVAL Park the machine on a flat surface and position the backhoe on the ground. Support the backhoe ele- ments for cylinder removal using a suitable stand. WARNING Always support the structural members so that they will be stable and safe to work around.
  • Page 670 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 cylin- der rod and finally reinsert the pin.
  • Page 671 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY CYLINDER 1. Wiper ring 11. O-ring 2. Bushing 12. Piston guide 3. Cylinder rod 13. Piston gasket 4. Wiper ring 14. Piston 5. Ring seal 15. Piston gasket 6. Ring seal 16.
  • Page 672 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Support the cylinder rod (3). Remove the safety screw (8). Use the wrench 380000724 to loose the cylinder head (9). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture. Extract the cylinder head (9) from the cylinder barrel (18) by tapping it with a plastic hammer.

  • Page 673: Backhoe Attachment Dipper Cylinder

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM BACKHOE ATTACHMENT DIPPER CYLINDER (1) Stroke (2) Completely retracted CYLINDER REMOVAL Park the machine on a flat surface and position the backhoe on the ground. Support the backhoe ele- ments for cylinder removal using a suitable stand. WARNING Always support the structural members so that they will be stable and safe to work around.
  • Page 674 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 re- tract the cylinder. In this way, the rod moves away from the attaching point.
  • Page 675 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY CYLINDER 1. Wiper ring 11. O-ring 2. Bushing 12. Piston gasket 3. Cylinder rod 13. Piston guide 4. Wiper ring 14. Piston 5. Ring seal 15. Washer 6. Ring seal 16. Screw 7.
  • Page 676 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Support the cylinder rod (3). Unscrew and remove the safety screw (8). Use the wrench 380000724 to loose the cylinder head (9). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture. Extract the cylinder head (9) from the cylinder barrel (17) by tapping it with a plastic hammer.

  • Page 677: Backhoe Bucket Cylinder

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM BACKHOE BUCKET CYLINDER (1) Stroke (2) Completely retracted CYLINDER REMOVAL Park the machine on a flat surface. Lay the backhoe bucket firmly on the ground. WARNING Always support the structural members so that they will be stable and safe to work around.
  • Page 678 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Remove the stop ring (1) with the shim (2). Slide out the pin (3) with an hammer and pay attention to le- vers. If necessary use hydraulic power to very slowly re- tract the cylinder.
  • Page 679 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY CYLINDER 1. Wiper ring 10. Back-up ring 2. Bushing 11. O-ring 3. Cylinder rod 12. Piston gasket 4. Wiper ring 13. Piston guide 5. Ring seal 14. Piston 6. Ring seal 15.
  • Page 680 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Support the cylinder rod (3). Remove the safety screw (8). Use the wrench 380000725 to loose the cylinder head (9). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture. Extract the cylinder head (9) from the cylinder barrel (16) by tapping it with a plastic hammer.

  • Page 681: Telescopic Cylinder

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM TELESCOPIC CYLINDER (1) Stroke (2) Completely retracted CYLINDER REMOVAL Park the machine on a flat surface and position the backhoe on the ground. Support the backhoe ele- ments for cylinder removal using a suitable stand. WARNING Always support the structural members so that they will be stable and safe to work around.
  • Page 682 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Disconnect the hydraulic hoses (3), at dipper cylin- der 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.
  • Page 683 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY CYLINDER 1. Cylinder rod 8. Back-up ring 2. Wiper ring 9. O-ring 3. Ring seal 10. Piston gasket 4. Ring seal 11. Piston guide 5. Guide bush 12. Piston 6. Safety screw 13.
  • Page 684 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Support the cylinder rod (1). Unscrew and remove the safety screw (6). Use the wrench 380000721 to loose the cylinder head (7). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture. Extract the cylinder head (7) from the cylinder barrel (14) by tapping it with a plastic hammer.

  • Page 685: 4Ws Stabilizer Cylinder - Center Pivot

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 4WS STABILIZER CYLINDER - CENTER PIVOT (1) Stroke (2) Completely retracted 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.
  • Page 686 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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).
  • Page 687 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY STABILIZER CYLINDER - CENTER PIVOT 1. Cylinder rod 8. Back-up ring 2. Wiper ring 9. O-ring 3. Ring seal 10. Piston gasket 4. Ring seal 11. Piston guide 5. Guide bush 12.
  • Page 688 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Support the cylinder rod (1). Unscrew and remove the safety screw (6). Use the wrench 380000726 to loose the cylinder head (7). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture. Extract the cylinder head (7) from the cylinder barrel (14) by tapping it with a plastic hammer.

  • Page 689: Stabilizer Cylinder - Sideshift

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM STABILIZER CYLINDER - SIDESHIFT (1) Stroke (2) Completely retracted CYLINDER REMOVAL Park the machine on a flat surface and position the bucket on the ground. Lower the stabilizers to the ground. Relieve possible residual pressures in the system by moving the loader attachment control lever through all operating positions.
  • Page 690 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Disconnect the hydraulic tubes at the top of the sta- bilizer. Remove the snap ring (4) and extract the pin (5). Screw in an eye screw (6) on the cylinder and con- nect a rope or a chain.
  • Page 691 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY CYLINDER 1. Cylinder rod 8. O-ring 2. Wiper ring 9. Piston 3. Ring seal 10. Piston guide 4. Ring seal 11. Piston gasket 5. Cylinder head 12. Screw 6. Snap ring 13.
  • Page 692 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Support the cylinder rod (1). Remove the stop ring (6). Use the wrench 380000721 to loose the cylinder head (5). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture. Extract the cylinder head (5) from the cylinder barrel (13) by tapping it with a plastic hammer.

  • Page 693: 5.10 Swing Cylinder

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 5.10 SWING CYLINDER (1) Stroke (2) Completely retracted CYLINDER REMOVAL Park the machine on a flat surface and position the backhoe on the ground. Support the backhoe ele- ments for cylinder removal using a suitable stand. WARNING Always support the structural members so that they will be stable and safe to work around.
  • Page 694 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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.
  • Page 695 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY CYLINDER 1. Bushing 10. Trunnion 2. Wiper ring 11. O-ring 3. Cylinder rod 12. Back-up ring 4. Wiper ring 13. Piston gasket 5. Ring seal 14. Piston guide 6. Ring seal 15.
  • Page 696 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM Use the wrench 380000725 to loose the trunnion (10). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture. Remove the rod assy with the trunnion and the pis- ton assy.
  • Page 697 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 5.11 BACKHOE ATTACHMENT SIDESHIFT CYLINDER - SIDESHIFT On the loader backhoe there are 4 sideshift lock cyl- inders for the backhoe attachment. Their function is to lock the carriage once the backhoe attachment is ready in the digging position.

  • Page 698: 5.12 Special Tools

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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...

  • Page 699: Specifications

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC CONTROL LEVERS SPECIFICATIONS Weight 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...
  • Page 700 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM DESCRIPTION AND OPERATION 1. CONTROL CANCELLATION SWITCH: with this 6. TELESCOPIC DIPPER CONTROLS: (propor- switch in the ON (alight) position, all the back- tional controls) (If fitted). hoe attachment hydraulic controls are function- Press the right-hand button to extend the tele- scopic dipper.
  • Page 701 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM RIGHT HAND HYDRAULIC CONTROL LEVER 1. Valve 10. Half handle 2. Plate 11. Cover 3. Screw 12. Switches 4. Nut 13. Washer 5. Boot 14. Spacer 6. Connector 15. Clip 7. Wedge 16.
  • Page 702 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM LEFT HAND CONTROL LEVER 1. Valve 11. Cover 2. Plate 12. Switch push button (horn) 3. Screw 13. Washer 4. Nut 14. Spacer 5. Boot 15. Clip 6. Connector 16. Clip 7. Wedge 17.
  • Page 703 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY AND ASSEMBLY 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 cancel- lation switch to the ON position. Move both joysticks in all directions.
  • Page 704 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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.
  • Page 705 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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).

  • Page 706: Control Lever Valve

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM CONTROL LEVER VALVE P. Supply T. Return to tank Right valve (dipper/bucket) Left valve (backhoe/swing) 1. Retracting the dipper 1. Lifting 2. Opening the backhoe bucket 2. Right swinging 3. Extending the dipper 3.
  • Page 707 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 1. Universal joint cam 12. Cover 2. Plate 13. Safety ring 3. Shim 14. Spring 4. Upper body 15. Spool 5. Rod guide 16. Shims 6. Ring seal 17. Valve 7. Ring seal 18.
  • Page 708 4. Remove the shim (3) from the upper body (4). that of removal. 5. Extract the rod guide (5) and replace the seal 2. In the case of reassembly without changing the rings (6) and (7). U/J cam (1), put the same value of shims (3) as 6.

  • Page 709: Fault Finding

    www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM FAULT FINDING 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 replace- ment could result.
  • Page 710 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM FAULT FINDING GENERAL PROBLEM CAUSE CORRECTION All systems fail to operate Pump drive inoperative 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.
  • Page 711 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM 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 sys- tems and the pump are correctly operating.
  • Page 712 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM SWING PROBLEM CAUSE CORRECTION Right or left direction swing fails Swing system relief valves not Test the swing system relief valve. to operate, is slow, or has loss of seating, set too low or seat power leaking Valve spool leakage...
  • Page 713 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC PUMP PROBLEM CAUSE CORRECTION System noisy Worn or damaged pump gears or Make a hydraulic pump performance pressure plates test. Aeration: air entering the systems at: suction tube, pump shaft, Make a hydraulic pump performance fittings or cylinder ring nuts test.
  • Page 714 www.maskinisten.net Copyright © SECTION 35 - HYDRAULIC SYSTEM NOTES:...
  • Page 715 Copyright © 580SR 580SR+ 590SR 695SR 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 .................
  • Page 716 www.maskinisten.net Copyright © SECTION 39 - CHASSIS...
  • Page 717 www.maskinisten.net Copyright © SECTION 39 - CHASSIS DESCRIPTION AND OPERATION This section can be used as a quick reference for general disassembly of the machine and its compo- nents. The chassis of the Backhoe Loader is manufactured as a one piece unit on which the major assemblies are attached or supported from.
  • Page 718 www.maskinisten.net Copyright © SECTION 39 - CHASSIS CENTER PIVOT 4WS CHASSIS SIDESHIFT 2WS CHASSIS SIDESHIFT 4WS CHASSIS...
  • Page 719 www.maskinisten.net Copyright © SECTION 39 - CHASSIS REMOVAL AND INSTALLATION COMPONENTS COMPONENTS WITHIN THE CHASSIS ENGINE Supported by 2 rubber silent blocks and held in po- To remove the engine/transmission from the ma- sition by 2 support brackets. The brackets, which chine it will be necessary to remove or disconnect are welded to the frame one either side of the en- the following:...
  • Page 720 www.maskinisten.net Copyright © SECTION 39 - CHASSIS COMPONENTS BELOW THE CHASSIS FRONT AXLE REAR AXLE The front axle is attached to the underside of the The rear axle is attached to the frame at the rear of chassis by 6 through screws (2WS) or 4 through the machine by 4 through bolts.
  • Page 721 www.maskinisten.net Copyright © SECTION 39 - CHASSIS 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...
  • Page 722 www.maskinisten.net Copyright © SECTION 39 - CHASSIS 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.
  • Page 723 www.maskinisten.net Copyright © SECTION 39 - CHASSIS COMPONENTS ATTACHED ON THE CHASSIS A. Front fixing 8. Washer B. Rear fixing 9. Cab floor S. Cab skirts 10. Cab support (rear) 1. Main frame 11. Support 2. Anti-vibration 12. Bushing 3. Dampener 13.
  • Page 724 www.maskinisten.net Copyright © SECTION 39 - CHASSIS 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.
  • Page 725 www.maskinisten.net Copyright © SECTION 39 - CHASSIS MOUNTING SCREW TORQUE 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.
  • Page 726 www.maskinisten.net Copyright © SECTION 39 - CHASSIS FRONT COUNTERWEIGHT COMPONENTS TORQUES Counterweight 700 Nm LOADER COMPONENTS TORQUES Loader control pipe bracket to frame 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...
  • Page 727 Copyright © 580SR 580SR+ 590SR 695SR SECTION 41 - STEERING SYSTEM 1. STEERING SYSTEM 2WS ........................... 4 2. STEERING SYSTEM 4WS ........................... 7 3. POWER STEERING ........................... 12 3.1 SPECIFICATIONS ..........................13 3.2 COMPONENTS ........................... 15 3.3 DISASSEMBLY AND ASSEMBLY....................... 16 3.4 SPECIAL TOOLS..........................
  • Page 728 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM...
  • Page 729 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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;...
  • Page 730 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM STEERING SYSTEM 2WS COMPONENTS 1. Flow divider 6. By-pass valve 2. Power steering 7. Radiator 3. Hydraulic tank 8. Front axle 4. Return manifold 5. Oil filter...
  • Page 731 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM POWER STEERING - NEUTRAL F29379 Pump pressure Trapped oil Stand-by pressure Return to oil tank When the steering wheel is held still, the leaf springs return and hold the power steering spool in the neu- tral position.
  • Page 732 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM POWER STEERING - TURNING RIGHT F29384 Pump pressure Trapped oil Metered pressure Return to oil tank When the steering wheel is turned, the movement of the power steering spool forms a series of passag- es.
  • Page 733 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM STEERING SYSTEM 4WS COMPONENTS 1. Flow divider (hydraulic pump) 6. By-pass valve 2. Power steering 7. Radiator 3. Hydraulic tank 8. Front axle 4. Return manifold 9. Steering control valve 5. Oil filter 10.
  • Page 734 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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.
  • Page 735 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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.
  • Page 736 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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).
  • Page 737 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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 be- low. These are also the pins which need to be pressed when changing steering mode manually in an emer- gency.

  • Page 738: Power Steering

    www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM POWER STEERING The steering unit consists of a metering pump that wheel, through column, that can be of two types: includes: fixed or adjustable. Z A gear wheel assembly with fixed stator (with inner Z A cardan shaft, mechanically tied to gear wheel as- teeth) and a rotor (with outer teeth).

  • Page 739: Specifications

    www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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 MOUNTING SCREW TORQUE 3/4 - 16 UNF 7/16 - 20 UNF Steering wheel nut Steering motor to steering column bracket...
  • Page 740 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM HYDRAULIC DIAGRAM 1. Power steering 4. Anti-shock valve set at 240 ÷ 260 bar 2. Power steering control valve 5. Anticavitation valve 3. Check valve...

  • Page 741: Components

    www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM COMPONENTS * Only with 4WS models 1. Sleeve 14. O-ring 2. Spool 15. End cover 3. Ball 16. Washer 4. Thread bushing 17. Special screw 5. O-ring 18. Screw 6. Bearing 19. Body 7.

  • Page 742: Disassembly And Assembly

    www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM DISASSEMBLY AND ASSEMBLY 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 O- ring seals, noting the connector positions. Remove the four screws from within the cab.
  • Page 743 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM Remove the end cover (15). Extract the rotor/stator gear (13) (with spacer, if fit- ted). Extract the two O-rings (14). Remove the cardan shaft (9). Remove the distributor plate (12).
  • Page 744 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM Screw out the threaded bush (4) over the check valve. Remove the O-ring (11). 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.
  • Page 745 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM Extract the ring (7), the races and the bearing (6) from the sleeve and the spool. The outer (thin) bear- ing race can sometimes “stick” in the housing, there- fore check that is has come out. Press out the cross pin (8).
  • Page 746 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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.
  • Page 747 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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.
  • Page 748 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM ASSEMBLY NOTE: great care should be taken during re-assem- bly. 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).
  • Page 749 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM Assemble spool and sleeve. When assembling spool and sleeve only one of two possible ways of positioning the spring slots is cor- rect. There are three slots in the spool and three holes in the sleeve in the end of the spool/sleeve op- posite to the end with spring slots.
  • Page 750 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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.
  • Page 751 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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.
  • Page 752 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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.
  • Page 753 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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.
  • Page 754 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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.
  • Page 755 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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.
  • Page 756 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM For precise keying and alignment of steering control valve, pay attention to the parallelism of (A), (B), (C) and (D) reference marks. A. Rotor/stator surface B. Distributor plate surface C. Pin axis D.
  • Page 757 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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 in- itial torque is 10.8 Nm.
  • Page 758 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM 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.

  • Page 759: Special Tools

    www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM SPECIAL TOOLS P/N CNH 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 CAUSE CORRECTION No steering or excessive effort Incorrect oil level in tank Fill with the correct oil type and...
  • Page 760 www.maskinisten.net Copyright © SECTION 41 - STEERING SYSTEM NOTES:...
  • Page 761 Copyright © 580SR 580SR+ 590SR 695SR SECTION 50 - CAB HEATING AND AIR CONDITIONING 1. SPECIFICATIONS ............................3 2. CAB HEATING.............................. 5 2.1 DESCRIPTION AND OPERATION......................5 3. AIR CONDITIONING ..........................12 3.1 PRINCIPALS OF AIR CONDITIONING ....................12 3.2 SAFETY PRECAUTIONS ........................
  • Page 762 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING...

  • Page 763: Specifications

    www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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...
  • Page 764 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING PERFORMANCE CALCULATED AT m/s (191.72 m Exchanged warmth 5.48 kW 4718.28 kcal/h Air outlet temperature 5.64 °C Air side load loss 2.97 daPa 0.30 mmH Coolant side load loss 13.1 kPa 0.13 bar PERFORMANCE CALCULATED AT 2.0 m/s (383.4 m...

  • Page 765: Cab Heating

    www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING CAB HEATING DESCRIPTION AND OPERATION 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.
  • Page 766 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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 condi- tions.
  • Page 767 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING F30058 Schematic - Heater system 1. Heater valve mounted to the right of the heater 5. Air intake to the heater housing from below the housing cab floor 2. Air ducting to the front windscreen 6.
  • Page 768 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING Electrical heater valve The electrical valve is equipped with a software that, each time the supply of the cock is delayed (there- fore also at backhoe loader start), carries out the mo- mentary positioning of the cock to “completely closed”...
  • Page 769 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING FAULT FINDING -GENERAL Items that may cause a concern are suggested in Hoses are unrestricted and not leaking. the fault finding chart but as a general rule apply the Check the electrical connections are good and the following steps: blower motor is operational.
  • Page 770 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING OVERHAUL IMPORTANT: when overhauling the heating system remember that, with the engine running or shortly af- ter it is turned off, the system will be at engine tem- perature and therefore the water will be hot and under pressure.
  • Page 771 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING Blower motor The blower motor (1) can be removed by removal of the attaching hardware and disconnection of the wir- ing connector. Check the blower is working, if not check fuse and continuity of blower motor.

  • Page 772: Air Conditioning

    www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING AIR CONDITIONING PRINCIPALS OF AIR CONDITIONING The function of the air conditioning system is to im- prove the operator’s comfort by cooling the air tem- perature inside the cab and reducing the humidity level.
  • Page 773 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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.
  • Page 774 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING Air conditioning principle of operation 1. Expansion valve-atomizes liquid refrigerant be- 3. Compressor-compresses and raises tempera- fore passing to evaporator ture of refrigerant gas 2. Evaporator-absorbs heat from air in cab 4.
  • Page 775 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING LOW PRESSURE SIDE HIGH PRESSURE SIDE EXPANSION VALVE TEMPERATURE HIGH PRESSURE LIQUID ATOMIZED LIQUID FILTERED AT A LOWER AND MOISTURE TEMPERATURE REMOVED RECEIVER DRYER LOWER TEMPERATURE EVAPORATOR HIGH PRESSURE LIQUID CONDENSER WARM LOW...

  • Page 776: Safety Precautions

    www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING By giving off heat to the outside air, the vapour is the cab warm air blown across the coils and fins by condensed to a liquid which moves under high pres- the cab blower motor.

  • Page 777: Controls And Operation

    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).
  • Page 778 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING OPERATION IMPORTANT: when using the air conditioning, it is essential that all the windows of the operator’s com- partment 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.
  • Page 779 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING COOLANT To achieve the absorption and the release of heat WARNING which is, in essence, the function of an air condition- ing system, requires the use of a suitable “refriger- If refrigerant should contact the skin use the same ant”...
  • Page 780 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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 pres- sure sides of the system and has two functions: 1.
  • Page 781 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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).
  • Page 782 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING CONDENSER The condenser (1), located at the front of the ma- chine in front of the engine radiator consists of a number of turns of continuous coil mounted in a se- ries of thin cooling fins to provide a maximum of heat transfer in a minimum amount of space.
  • Page 783 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING EXPANSION VALVE The expansion valve is located underneath the evaporator in the pressure line leading from the re- ceiver/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 liq- uid.
  • Page 784 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING When the system is started, the pressure on the bot- tom of the diaphragm lowers rapidly, allowing the or- ifice 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 tem-...
  • Page 785 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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.

  • Page 786: Fault Finding And Testing

    www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING FAULT FINDING AND TESTING Preliminary fault finding Always conduct the preliminary fault finding checks Overhaul of the air conditioning system should only before performance testing the system. be undertaken by a certified specialist refrigeration 1.
  • Page 787 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING Attaching The Gauge Set To The Loader Backhoe 1. Low side gauge 6. Test Hose to Low Side Service Connector 2. High side gauge 7. Shut-off Valve 3. Shut-off Valve 8.
  • Page 788 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING Attaching The Gauge Set To The Loader Backhoe 1. Apply the parking brake, check the gearshift le- vers are in neutral and close the cab windows WARNING and doors. 2.
  • Page 789 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING PERFORMANCE TEST DIAGNOSIS Pressure gauge values: Low pressure - Low High Pressure - Low PROBLEM POSSIBLE CAUSE CORRECTION Evaporator air not cold Low refrigerant charge Perform leak tests and repair. Evacuate the system.
  • Page 790 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING PERFORMANCE TEST DIAGNOSIS CHART Pressure gauge values: Low pressure - High High Pressure - High PROBLEM POSSIBLE CAUSE CORRECTION Evaporator air warm Improper operation of condenser Inspect for dirty condenser restricting Liquid line hot (condenser out- air flow and cooling.
  • Page 791 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING PERFORMANCE TEST DIAGNOSIS CHART Pressure gauge values: Low pressure - High High Pressure - Low PROBLEM POSSIBLE CAUSE CORRECTION Evaporator air not cold Internal leak in compressor (reed Discharge the system. valves, gasket, worn or scored pis- Replace the compressor.
  • Page 792 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING EXAMPLES OF MANIFOLD GAUGE READINGS AND INTERPRETATIONS The following examples show typical low and high pressure gauge readings obtained when performance test- ing 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.
  • Page 793 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING PERFORMANCE TEST EXAMPLE 2 F28698 Performance Test Example 2 1. High side low 5. Low side hose connected to low side service 2. High side hand valve closed connector 3.
  • Page 794 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING PERFORMANCE TEST EXAMPLE 3 F28699 Performance Test Example 3 1. High side normal 5. Low side hose connected to low side service 2. High side hand valve closed connector 3.
  • Page 795 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING PERFORMANCE TEST EXAMPLE 4 F28700 Performance Test Example 4 1. High side low 5. Low side hose connected to low side service 2. High side hand valve closed connector 3.
  • Page 796 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING PERFORMANCE TEST EXAMPLE 5 F28701 Performance Test Example 4 1. High side high 5. Low side hose connected to low side service 2. High side hand valve closed connector 3.
  • Page 797 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING PERFORMANCE TEST EXAMPLE 6 F28701 Performance Test Example 6 1. High side normal 5. Low side hose connected to low side service 2. High side hand valve closed connector 3.
  • Page 798 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING PERFORMANCE TEST EXAMPLE 7 F28704 Performance Test Example 7 1. High side high 5. Low side hose connected to low side service 2. High side hand valve closed connector 3.
  • Page 799 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING PERFORMANCE TEST EXAMPLE 8 F28705 Performance Test Example 8 1. High side low 5. Low side hose connected to low side service 2. High side hand valve closed connector 3.
  • Page 800 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING PERFORMANCE TEST EXAMPLE 9 F28706 Performance Test Example 9 1. High side low 5. Low side hose connected to low side service 2. High side hand valve closed connector 3.
  • Page 801 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING PERFORMANCE TEST EXAMPLE 10 F28707 Performance Test Example 10 1. High side normal 5. Low side hose connected to low side service 2. High side hand valve closed connector 3.
  • Page 802 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING LEAK TESTING, DISCHARGING AND CHARGING THE AIR CONDITIONING SYSTEM Leak Testing To perform a leak test if refrigerant leakage is sus- pected, use a leak detector following the manufac- turer’s instructions.
  • Page 803 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING Connecting recovery evacuation and recycling/charging station to the loader backhoe 1. Built in manifold gauge set 3. Low side (suction) service valve (blue hose) 2. Recovery/recharging unit 4. High side (discharge) service valve (red hose) Other recovery systems are available where the NOTE: if a unit requiring the manifold gauge set is manifold gauges are not an integral part of the ma-...

  • Page 804: Flushing The System

    www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING FLUSHING THE SYSTEM F28711 Manifold side gauge 1. High side gauge 5. Low side hose 2. High side shut-off valve 6. Low side shut-off valve 3. High side hose 7.
  • Page 805 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING NOTE: never use any solvent for flushing an air con- ditioning system other than a special flush solvent made specifically for air conditioning systems. Al- ways follow the manufacturer’s recommendations and directions for using the flushing equipment and solvent.

  • Page 806: Evacuating The System

    www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING EVACUATING THE SYSTEM 2. If a combined recovery/evacuation unit is to be IMPORTANT: a system in which the refrigerant has used attach the unit to the air conditioning sys- been recovered to facilitate repairs, must be evacu- tem in accordance with the manufacturers in- ated before new refrigerant is installed.

  • Page 807: Charging The System

    www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING CHARGING THE SYSTEM pull the remainder of the refrigerant into the sys- tem. 5. If the refrigerant charge will not completely IMPORTANT: be sure there are no leaks in the sys- transfer to the air conditioning system, recover tem and the system has been fully evacuated.

  • Page 808: Components Overhaul

    www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING COMPONENTS OVERHAUL GENERAL WARNING Before disconnecting components in the air condi- tioning system the refrigerant gas must be dis- charged and recovered using a certified recovery system. Refer to Discharging the system. Do Not discharge the gas into the atmosphere.
  • Page 809 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING EVAPORATOR 1. Discharge and reclaim refrigerant gas using cer- tified recovery systems. 2. Remove the seat and cover plate to reveal evap- orator assembly (1). 3. Remove temperature cycling control thermocou- ple.
  • Page 810 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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 re- placed without discharging the system.
  • Page 811 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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). Re- move the fuel cooler (6).
  • Page 812 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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 blow- er 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 un- derside of the filter.

  • Page 813: Compressor

    www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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...
  • Page 814 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING FAULT FINDING During diagnosis follow the inspections procedures in the sequence shown until a default is found. Then per- form the repair in the “Cause and Remedy” section. If this repair does not fully solve the problem, proceed to the next inspection step.
  • Page 815 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION F28721 Removal Discharge the air conditioning system. Disconnect the electrical harness of the compressor (12) from the electrical harness of the engine. Disconnect tub- ing to compressor. Remove the washer (7) and the screw (1).
  • Page 816 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING Remove the washers (5), the nut (6), the screw (2) and the block (8). Remove the screw (1), the wash- ers (3) and the belt tensioner (4). Remove the screw (10), the washers (2) and the compressor (12).
  • Page 817 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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 F28726 OVERHAUL COMPRESSOR...
  • Page 818 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING CLUTCH F28729 1. Cover screw 6. Cover 2. Dust cover 7. Snap ring 3. Nut 8. Rotor assembly 4. Plate 9. Snap ring 5. Shims 10. Field coil Disassembly All clutch servicing should be done with the com- pressor removed from the vehicle.
  • Page 819 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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.
  • Page 820 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING Lift the coil (10) from the housing and replace as re- quired. F28736 Assembly Install the coil (10), making sure that the wire is lo- cated behind the clip on the outside of the body and that the snap ring (9) is located in the groove.
  • Page 821 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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 circumfer- ence and be between 0.4-0.8 mm.
  • Page 822 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING COMPRESSOR F28743 Air conditioning refrigerant compressor 1. Shaft key 6. Gasket 2. Ring 7. Plate 3. Circlip 8. Head gasket 4. Gasket 9. Cylinder head 5. Plug 10. Screw Removal The refrigerant must be discharged from the system and the compressor removed from the vehicle prior...
  • Page 823 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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 re- frigerant oil and attach to the seal remover/installer tool.
  • Page 824 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING Position the shims over the shaft and refit the shaft key. Reinstall the plate as described in clutch reassem- bly. F28911...
  • Page 825 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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.
  • Page 826 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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.

  • Page 827: 3.10 Special Tools

    www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING 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.
  • Page 828 www.maskinisten.net Copyright © SECTION 50 - CAB HEATING AND AIR CONDITIONING NOTES:...
  • Page 829 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........................
  • Page 830 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 5. STARTING SYSTEM ..........................134 5.1 DESCRIPTION AND OPERATION....................134 5.2 FAULT FINDING ..........................135 5.3 STARTER MOTOR ..........................138 6. ALTERNATOR ............................144 6.1 SPECIFICATIONS ..........................144 6.2 DESCRIPTION AND OPERATION....................144 6.3 COMPONENTS ..........................
  • Page 831 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM GENERALITIES 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 ca- bles 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 dam- age electrical components.
  • Page 832 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM FAULT FINDING PROBLEM CAUSE CORRECTION Electrical system is inoperative Loose or corroded battery Check that the battery voltage with connections open circuit is at least 12.6 V. Check the electrolyte level and Clean and tighten connections density.
  • Page 833 Copyright © SECTION 55 - ELECTRICAL SYSTEM ELECTRICAL DIAGRAMS ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (580SR) FUSE AND RELAY DESCRIPTION Forward-reverse travel gearshift lever relay Parking brake relay Fuse Rating Function Starting relay Bucket level solenoid valve relay 7.5 A...
  • Page 834 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM COMPONENTS AND CONNECTORS NAME DESCRIPTION NAME DESCRIPTION Fuse and relay control unit Alarm buzzer Starter motor Double delivery solenoid valve (optional) Air conditioning compressor (not Hand hammer control valve (optional) connected) Rear hammer solenoid valve (optional) Engine water temperature sender Backhoe attachment travel solenoid Fuel level gauge...
  • Page 835 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NAME DESCRIPTION NAME DESCRIPTION 4x1 bucket control lever Front right work light - 4-way connector General line - engine line - 18-way Front right work light (optional) - 4-way connector connector “Grid heater” - 6-way connector Rear left work light (optional) - 4-way connector Engine stop - 1-way connector...
  • Page 836 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NAME DESCRIPTION Control unit - 17-way connector Control unit - 13-way connector Engine stop diode - 2-way connector Parking brake diode - 2-way connector XST2 Side instrument cluster - 36-way connector Proportional solenoid valves...
  • Page 837 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM ENGINE LINE DIAGRAM...
  • Page 838 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM R-N1 G/R1 7,5A 86 87a 86 87a 86 87a 86 87a 86 87a L-N1 R-V1 R-V1 EV10 TO PILOT CONTROL HORN F27480...
  • Page 839 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM...
  • Page 840 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM LIGHT LINE DIAGRAM...
  • Page 841 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM REAR LIGHT LINE DIAGRAM...
  • Page 842 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM WORK LIGHT LINE DIAGRAM...
  • Page 843 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM WINDSHIELD WIPER - WASHER LINE DIAGRAM...
  • Page 844 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM HEATER LINE R-N1 G/N1 R-N1 F27499...
  • Page 845 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM COLD START DIAGRAM CONTROLLER RELAY TO ENGINE LINE F27176...
  • Page 846 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SIDE INSTRUMENT CLUSTER Calibrations Gage type Input Reading Pointer Input tolerance Calibration tolerance direction 0 HZ 0 rpm ±3° Descending Speedometer 307 HZ 1000 rpm ± 60 rpm Ascending 736 HZ 2400 rpm ±...
  • Page 847 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM PIN # NAME FUNCTION WARNING LAMP No. Ignition 10V-16V INPUT Low oil pressure Low side switch input Air filter restriction Low side switch input Parking brake Low side switch input Alternator Alternator D+ input Not used Crab steer Low side switch input...
  • Page 848 Copyright © SECTION 55 - ELECTRICAL SYSTEM ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR) FUSE AND RELAY DESCRIPTION Forward-reverse travel gearshift lever relay Parking brake relay Fuse No. Rating Function Starting relay Rear windshield wiper and rear 15 A windshield washer...
  • Page 849 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM COMPONENTS AND CONNECTORS NAME DESCRIPTION NAME DESCRIPTION Inner rear left work light (optional) Right speaker (optional) Inner rear right work light (optional) Left speaker (optional) Reverse buzzer Alarm buzzer Horn Double delivery solenoid valve (optional) Optional buzzer Hand hammer control valve (optional) Starting relay...
  • Page 850 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NAME DESCRIPTION NAME DESCRIPTION Stop light switch Backhoe attachment travel lock solenoid valve - 2-way connector Stop light switch Backhoe attachment lock solenoid valve - Left cab light switch 2-way connector Right cab light switch Bucket sensor - 3-way connector Gearshift lever Pilot control audible alarm button - 2-way...
  • Page 851 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NAME DESCRIPTION NAME DESCRIPTION Front left direction indicator arrangement - Control unit - 17-way on-board connector 4-way connector Control unit - 13-way on-board connector Radio (brown) - 8-way connector Engine stop diode - 2-way connector Radio (black) - 8-way connector Parking brake diode - 2-way connector Electrical socket - 2-way connector...
  • Page 852 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM ENGINE LINE DIAGRAM...
  • Page 853 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM R-N1 G/R1 7,5A 86 87a 86 87a 86 87a 86 87a 86 87a L-N1 R-V1 R-V1 EV10 TO PILOT CONTROL HORN F27480...
  • Page 854 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM...
  • Page 855 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM LIGHT LINE DIAGRAM G-R1 15/1 30/3 C B A 49/4 30b/2 49a/5 L-N1 H/R1 V-N1.5 B-V1 7,5A 86 87a X101 X101 X101 X101 X101 F27482...
  • Page 856 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM REAR LIGHT LINE DIAGRAM R-N1 F27483...
  • Page 857 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM WORK LIGHT LINE DIAGRAM C/N1 C/N1 C/B1 86 87a 86 87a 86 87a 86 87a C/B1 F27484...
  • Page 858 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM WINDSHIELD WASHER/WIPER LINE DIAGRAM R-N1 C/N1 C/N1 57/58 54S 54D 53 31b L-N1 G/R1 V-N1.5 C-N1 6A A.R. 7,5A F27485...
  • Page 859 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM HEATER AND RADIO LINE DIAGRAM G-V1.5 R-N1 R-N1 G/N1 X110 X111 F27486...
  • Page 860 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM COLD START DIAGRAM CONTROLLER RELAY TO ENGINE LINE F27176...
  • Page 861 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SIDE INSTRUMENT CLUSTER Calibrations Gage type Input Reading Pointer Input tolerance Calibration tolerance direction 0 HZ 0 rpm ±3° Descending Speedometer 307 HZ 1000 rpm ± 60 rpm Ascending 736 HZ 2400 rpm ±...
  • Page 862 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM PIN # NAME FUNCTION WARNING LAMP No. Ignition 10V-16V INPUT Low oil pressure Low side switch input Air filter restriction Low side switch input Parking brake Low side switch input Alternator Alternator D+ input Not used Crab steer Low side switch input...
  • Page 863 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM AIR CONDITIONER SCHEMATIC I H ML C X110 X111 10 11 X111 X110 pos 8 F27181 Evaporator box 11-way connector 3rd speed relay Potentiometer Fuse 25 A Speed switch Ventilated electrical motor Temperature switch 1 and 2 speed resistor 12 V light...
  • Page 864 Copyright © SECTION 55 - ELECTRICAL SYSTEM ELECTRICAL DIAGRAMS - POWERSHIFT CAB (580SR) FUSE AND RELAY DESCRIPTION Forward travel relay, parking brake Starting relay Fuse Rating Circuit Bucket level solenoid valve relay Low and main beam relay Rear windshield wiper and rear...
  • Page 865 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM COMPONENTS AND CONNECTORS NAME DESCRIPTION NAME DESCRIPTION Reverse buzzer Right speaker (optional) Horn Left speaker (optional) Optional buzzer Alarm buzzer Starting relay Fuel shut off solenoid valve A/C relay Double delivery solenoid valve (optional) Antitheft unit Hand hammer control valve (optional) Transmission detachment relay...
  • Page 866 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NAME DESCRIPTION NAME DESCRIPTION Left cab light switch Backhoe attachment lock solenoid valve - 2-way connector Right cab light switch Bucket sensor - 3-way connector A/C pressure switch Pilot control audible alarm button - 2-way Light / windshield wiper control lever connector Warning switch...
  • Page 867 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NAME DESCRIPTION NAME DESCRIPTION Front left work light - 4-way connector Control unit - 21-way connector Front left direction indicator arrangement - Control unit - 17-way connector 4-way connector Control unit - 13-way connector Radio (brown) - 8-way connector Engine stop diode - 2-way connector Radio (black) - 8-way connector...
  • Page 868 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM ENGINE LINE DIAGRAM...
  • Page 869 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM R-N1 G/R1 A-B1 7,5A 7.5A 86 87a L-N1 F27489...
  • Page 870 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM...
  • Page 871 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM LIGHT LINE DIAGRAM R/N1 15/1 30/3 C B A 49/4 30b/2 49a/5 L-N1 V-N1.5 G-R1 B/R1 B-V1 H/R1 +30 +15 7,5A 86 87a A-B1 X101 X101 X101 X101 X101 F27491...
  • Page 872 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM REAR LIGHT LINE DIAGRAM R-N1 B/R1 F27492...
  • Page 873 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM WORK LIGHT LINE DIAGRAM C/N1 C/N1 C/B1 C/B1 86 87a C/B1 F27493...
  • Page 874 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM WINDSHIELD WIPER WASHER LINE R-N1 C/N1 C/N1 57/58 54S 54D 53 31b L-N1 G/R1 V-N1.5 C-N1 6A A.R. 7,5A F27494...
  • Page 875 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM HEATER LINE G-V1.5 R-N1 R-N1 G/N1 X110 X111 F27486...
  • Page 876 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM COLD START DIAGRAM CONTROLLER RELAY TO ENGINE LINE F27176...
  • Page 877 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SIDE INSTRUMENT CLUSTER Calibrations Gage type Input Reading Pointer Input tolerance Calibration tolerance direction 0 HZ 0 rpm ±3° Descending Speedometer 307 HZ 1000 rpm ± 60 rpm Ascending 736 HZ 2400 rpm ±...
  • Page 878 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM PIN # NAME FUNCTION WARNING LAMP No. Ignition 10V-16V INPUT Low oil pressure Low side switch input Air filter restriction Low side switch input Parking brake Low side switch input Alternator Alternator D+ input Not used Crab steer Low side switch input...
  • Page 879 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM AIR CONDITIONER SCHEMATIC Evaporator box 11-way connector 3rd speed relay Potentiometer Fuse 25 A Speed switch Ventilated electrical motor Temperature switch 1 and 2 speed resistor 12 V light Electrical cock 2-way waterproof connection X111 9-way connector 5-way waterproof connection...
  • Page 880 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM PILOT SCHEMATIC SAFETY RIGHT LEFT TO SOLENOID SWITCH JOYSTICK JOYSTICK VALVES LINE YP10 YP10 LEFT JOYSTICK PILOT ON/OFF PATTERN SWITCH SWITCH F27182...
  • Page 881 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NAME DESCRIPTION Safety relay Pilot ON/OFF switch - 8-way connector Gearshift configuration switch - 8-way connector Valve configuration “1” - 2-way connector Valve configuration “2” - 2-way connector Left hydraulic control lever - 2-way connector Left stabilizer pressure switch - 2-way connector...
  • Page 882 Copyright © SECTION 55 - ELECTRICAL SYSTEM ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR+/590SR) FUSE AND RELAY DESCRIPTION Forward-reverse travel gearshift lever relay Starting relay Rating Function Fuse No. Bucket level solenoid valve relay Rear windshield wiper and rear 15 A...
  • Page 883 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM COMPONENTS AND CONNECTORS NAME DESCRIPTION NAME DESCRIPTION Fuse A/C Right speaker (optional) Battery Left speaker (optional) Alternator Radio (optional) Reverse buzzer A106 Engine control unit Audible alarm B107 Water in fuel sensor Horn Air filter pressure switch K102...
  • Page 884 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NAME DESCRIPTION NAME DESCRIPTION Battery master switch Anti-theft device - 11-way connector Side instrument cluster X15.1 Start - connector 4x1 bucket control lever X15.6 Start - connector Forward speed solenoid valve Optional seat - 4-way connector Reverse travel solenoid valve Diagnostics - 10-way connector 4x1 bucket solenoid valves (optional)
  • Page 885 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NAME DESCRIPTION NAME DESCRIPTION Left direction indicator - 4-way connector Fuse and relay control unit line interface - general line - 17-way connector Air conditioning switch - 1-way connector Fuse and relay control unit line interface - Alternator - 3-way connector general line - 13-way connector Air conditioning pressure switch - 2-way...
  • Page 886 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM ENGINE LINE DIAGRAM...
  • Page 887 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM...
  • Page 888 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM...
  • Page 889 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM LIGHT LINE DIAGRAM...
  • Page 890 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM REAR LIGHT LINE DIAGRAM...
  • Page 891 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM WORK LIGHT LINE DIAGRAM...
  • Page 892 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM WINDSHIELD WASHER/WIPER LINE DIAGRAM...
  • Page 893 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM HEATER LINE...
  • Page 894 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM AIR CONDITIONER SCHEMATIC Evaporator box 11-way connector 3rd speed relay Potentiometer Fuse 25 A Speed switch Ventilated electrical motor Temperature switch 1 and 2 speed resistor 12 V light Electrical cock 2-way waterproof connection X111 9-way connector 5-way waterproof connection...
  • Page 895 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SIDE INSTRUMENT CLUSTER Calibrations Gage type Input Reading Pointer Input tolerance Calibration tolerance direction 0 HZ 0 rpm ±3° Descending Speedometer 307 HZ 1000 rpm ± 60 rpm Ascending 736 HZ 2400 rpm ±...
  • Page 896 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM CONNECTORS FUNCTION NOTE FUNCTION NOTE Not used Keep alive power Need to fuse at 1 ampere Key on power Wake up without In gear input Digital input disconnect Driving lights Digital input Not used Front work lights Digital input...
  • Page 897 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM ELECTRICAL DIAGRAMS - POWERSHIFT CAB (590SR) FUSE AND RELAY DESCRIPTION Flasher Starting relay Fuse Rating Circuit Bucket level solenoid valve relay Low and main beam relay Rear windshield wiper and rear wind- 15 A shield washer Inner front work light relay...
  • Page 898 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM COMPONENTS AND CONNECTORS NAME DESCRIPTION NAME DESCRIPTION Fuse A/C Right speaker (optional) Battery Left speaker (optional) Alternator Reverse buzzer Radio (optional) Audible alarm A106 Engine control unit Horn A107 Water in fuel sensor Transmission relay Air filter switch K102...
  • Page 899 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NAME DESCRIPTION NAME DESCRIPTION Battery master switch 6-way connector Side instrument cluster Front right lights - 4-way connector 4x1 bucket control lever Front left ìlights - 4-way connector General engine line interface - 18-way Front left direction indicator - 4-way connector connector...
  • Page 900 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NAME DESCRIPTION Speed control solenoid valve (optional) - 2- X207 way connector X208 Loader bucket - 2-way connector Rear hammer solenoid valve - 2-way X209 connector Transmissione disconnect - 2-way X210 connector Fuse and relay control unit line interface - general line - 11-way connector Fuse and relay control unit line interface -...
  • Page 901 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM ENGINE LINE DIAGRAM...
  • Page 902 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM...
  • Page 903 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM...
  • Page 904 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM LIGHT LINE DIAGRAM...
  • Page 905 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM REAR LIGHT LINE DIAGRAM...
  • Page 906 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM WORK LIGHT LINE DIAGRAM...
  • Page 907 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM WINDSHIELD WASHER/WIPER LINE DIAGRAM...
  • Page 908 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM HEATER LINE...
  • Page 909 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM AIR CONDITIONER SCHEMATIC Evaporator box 11-way connector 3rd speed relay Potentiometer Fuse 25 A Speed switch Ventilated electrical motor Temperature switch 1 and 2 speed resistor 12 V light Electrical cock 2-way waterproof connection X111 9-way connector 5-way waterproof connection...
  • Page 910 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SIDE INSTRUMENT CLUSTER Calibrations GAGE TYPE INPUT READING TOLERANCE 320 OHMS Empty - minimum reading +0/-2° FUEL LEVEL 185 OHMS Right - edge of red band ± 3° (Ref) 6.5 OHMS Full - maximum reading +4/-0°...
  • Page 911 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM CONNECTORS FUNCTION NOTE FUNCTION NOTE Not used Keep alive power Need to fuse at 1 ampere Key on power Wake up without In gear input Digital input disconnect Driving lights Digital input Not used Front work lights Digital input...
  • Page 912 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM ELECTRICAL DIAGRAMS - 4WS POWERSHIFT CAB (695SR) FUSE AND RELAY DESCRIPTION Hazard warning lights Fuse Rating Function Buzzer Rear windshield wiper and rear wind- Starting relay 15 A shield washer Bucket level solenoid valve relay Engine stop, (+15) anti-theft device, (+15) 7.5 A Low and main beam relay...
  • Page 913 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM COMPONENTS AND CONNECTORS NAME DESCRIPTION NAME DESCRIPTION Fuse for anti-theft device, diagnostic Right speaker (optional) socket, menu scroll switch, display enter Left speaker (optional) switch, side instrument cluster Fuse A/C Radio (optional) Battery A106 Engine control unit...
  • Page 914 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NAME DESCRIPTION NAME DESCRIPTION S140 Backhoe attachment travel lock switch Rear hammer button - 2-way connector S141 Front work light switches Rear right light - 4-way connector S144 Beacon lamp switch Rear right light - 4-way connector S160 Rear horn switches Rear windshield wiper motor - 4-way...
  • Page 915 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NAME DESCRIPTION NAME DESCRIPTION X110 Air conditioning - 3-way connector 2WS steering solenoid valve X111 Air conditioning - 9-way connector Y206 Bucket level solenoid valve X124 Quick coupler X128 Optional X130 12-way connector X132 6-way connector X144...
  • Page 916 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM ENGINE LINE DIAGRAM...
  • Page 917 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM...
  • Page 918 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM...
  • Page 919 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM LIGHT LINE DIAGRAM...
  • Page 920 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM REAR LIGHT LINE DIAGRAM...
  • Page 921 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM WORK LIGHT LINE DIAGRAM...
  • Page 922 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM WINDSHIELD WASHER/WIPER LINE DIAGRAM...
  • Page 923 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM HEATER LINE...
  • Page 924 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM STEERING LINE DIAGRAM...
  • Page 925 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM AIR CONDITIONER SCHEMATIC Evaporator box 11-way connector 3rd speed relay Potentiometer Fuse 25 A Speed switch Ventilated electrical motor Temperature switch 1 and 2 speed resistor 12 V light Electrical cock 2-way waterproof connection X111 9-way connector 5-way waterproof connection...
  • Page 926 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SIDE INSTRUMENT CLUSTER Calibrations GAGE TYPE INPUT READING TOLERANCE 320 OHMS Empty - minimum reading +0/-2° FUEL LEVEL 185 OHMS Right - edge of red band ± 3° (Ref) 6.5 OHMS Full - maximum reading +4/-0°...
  • Page 927 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM CONNECTORS FUNCTION NOTE FUNCTION NOTE Not used Keep alive power Need to fuse at 1 ampere Key on power Wake up without In gear input Digital input disconnect Driving lights Digital input Not used Front work lights Digital input...
  • Page 928 Copyright © SECTION 55 - ELECTRICAL SYSTEM CONTROLS AND INSTRUMENTS FRONT CONTROL PANELS (580SR / 590SR) 1. 2WD/4WD SWITCH 2. HAND-HELD AUXILIARY HYDRAULIC AT- This switch is used to engage or disengage the TACHMENT SWITCH (Optional) four wheel drive.
  • Page 929 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 6. HYDRAULIC SPEED CONTROL SWITCH (If 9. HORN BUTTON fitted) (Powershift transmission) This switch enables an increase in the moving This hold-down switch operates the warning speed of the loader and backhoe attachment. horn.
  • Page 930 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM FRONT CONTROL PANELS (695SR) 1. 2WD/4WD SWITCH 2. HAND-HELD AUXILIARY HYDRAULIC AT- This switch is used to engage or disengage the TACHMENT SWITCH (Optional) four wheel drive. This switch has two positions: This switch has three positions: - The first position is OFF.
  • Page 931 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 8. MANUAL MODE SELECTION SWITCH IMPORTANT: before undertaking any road travel, (Powershift transmission) select “Road” mode and fold back the cover to lock In situations where manual gearshifting (up or the switch in this position. downshift) is required, the automatic gearshift of the powershift transmission can be overridden 5.
  • Page 932 Copyright © SECTION 55 - ELECTRICAL SYSTEM SIDE INSTRUMENT CLUSTER PANEL (580SR) 1. FRONT WORK LIGHT SWITCH (ON position and lamp turned on). This switch has three positions: In this condition, the audible alarm will sound by - The first position is OFF.
  • Page 933 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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 wip- er is activated and will continue operating until the switch is returned to the OFF position.
  • Page 934 Copyright © SECTION 55 - ELECTRICAL SYSTEM SIDE INSTRUMENT CLUSTER PANEL (580SR+ / 590SR / 695SR) 1. FRONT WORK LIGHT SWITCH over protection device by pressing the switch This switch has three positions: (ON position and lamp turned on).
  • Page 935 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM NOTE: never use the work lights during road travel. 6. SIDE INSTRUMENT CLUSTER 7. HORN BUTTON (Powershift transmission) This hold-down switch operates the warning 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.
  • Page 936 Copyright © SECTION 55 - ELECTRICAL SYSTEM SIDE INSTRUMENT CLUSTER (580SR) 1. BRAKE LIQUID LEVEL WARNING LAMP 6. ENGINE OIL PRESSURE WARNING LAMP This lamp turns on and the audible warning de- This warning lamp turns on and the audible...
  • Page 937 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 9. PARKING BRAKE INDICATOR LAMP 16. TACHOMETER This indicator lamp turns on when the parking The tachometer shows the engine speed in rev- brake lever is in the raised position (wheels olutions per minute. braked).
  • Page 938 Copyright © SECTION 55 - ELECTRICAL SYSTEM SIDE INSTRUMENT CLUSTER (580SR+ / 590SR / 695SR) 1. CAUTION MASTER LAMP 6. “FOUR WHEEL STEER” (4WS) STEER INDI- This lamp signals a not critical caution. CATOR LAMP When this caution is active, it is necessary to...
  • Page 939 If the needle is in the left red ar- If this is not the case, the machine can get dam- ea, this shows that the battery charge is insuffi- aged or accidents may occur.
  • Page 940 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM IMMOBILISER CIRCUIT F28667 A. M38 Immobiliser E. Starter motor B. Electronic key socket with LED F. + 15 key positive C. 2 piece electronic key G. Electronic key D. + 50 to ignition Wire Function Connection...
  • Page 941 Copyright © SECTION 55 - ELECTRICAL SYSTEM 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 follow- ing: Z UP/DOWN SWITCH (2)
  • Page 942 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SYMBOLS Hydraulic oil filter blocked Work hours Transmission oil pressure too high Maintenance Battery charging failure Maintenance heavy (hours) HEAVY 1000 Contaminated fuel Maintenance light (hours) LIGHT Malfunction Stored error code Back-light dimming “Grid heater”...
  • Page 943 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM SETUP MENU Dimmer Increase Decrease Increase Decrease Service interval Increase Decrease Total no. of pages Stored error CODE OCCUR- code RENCE 3-second scroll unless the up/ down button is pressed Presence of Select / Deselect “grid heater”...
  • Page 944 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM PROCEDURE ABOUT SELF TEST Power up LCD and show work Any of the above at with ignition Foot max: X.X. hours for 10 seconds Foot min: X.X. 113/111 range Go to menu Hand max: X.X.
  • Page 945 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM ON BOARD ERROR CODE RETRIEVAL MAIN SCREEN ↵ Stored error code Page 1/6 3-second scroll unless CODE 3059 the up/down button is ↵ OCCURRENCE 3 pressed TIME 1004.5 Page 2/6 CODE 3009 OCCURRENCE 2 TIME 1010.6...
  • Page 946 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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 back- lighting will be achieved by LEDs and dimming shall be provided through the setup menu selections.
  • Page 947 0.0 until 210,554,060.7 using a step of 6 min- milliseconds): when the value reaches a multiple of utes. In case of battery disconnection, the cluster 10, the increment/decrement rate is 10 units every can lose 0.1 hour or 6 minutes max.
  • Page 948 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM FUNCTIONAL DESCRIPTION Auto wake up at every 600 ms for sensing a change With the key OFF, all indicators must be set to the in ENTER, DISPLAY, UP or DOWN switch status parking position.
  • Page 949 A stepper motor will drive the ta- Both the movements have to be uniform. chometer. Needle calibration has never to be lost for The behavior of the gauge in case of faulty sensor any external condition. will be to return to the parked position. Since this The message to be used is EEC1.
  • Page 950 This is necessary due to the cool temperatures present when the unit is working in backhoe position. In case the sender is disconnect- ed, the gauge has to go down to home position. Re- connecting the sensor will make the error code inactive and the gauge has to return to the correct position.
  • Page 951 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.
  • Page 952 2. There are conditions in which the diagnostic de- tects 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...
  • Page 953 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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.
  • Page 954 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM MAINTENANCE Two different kinds of maintenance will be available: HEAVY MAINTENANCE Z light maintenance; From 10 hours before the set value, display on the Z heavy maintenance. display the “heavy maintenance symbol” at every key on and should last for one second after crank- LIGHT MAINTENANCE ing.
  • Page 955 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 4.10 WARNING MESSAGES Function Lamp Alarm Lamp Display Condition Description Priority Color lamp Coolant Engine Coolant temperature coolant too Continuous above 112 °C 1002 VCM STOP signal - Above high for 5 seconds normal Oil pressure Engine oil...
  • Page 956 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM Function Lamp Alarm Lamp Display Condition Description Priority Color lamp General Only display DTC’s 3000 - display Continuous with display STOP STOP 3366 message request One touch AUTO idle active n/min Parking Continuous, Switch This prevents...
  • Page 957 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM Function Lamp Alarm Lamp Display Condition Description Priority Color lamp Foot Foot One second Accelerator accelerator accelerator alarm every above 4.75 V 1011 VCM Amber signal out sensor -signal 30 seconds for 5 seconds of range above range Foot...
  • Page 958 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM Function Lamp Alarm Lamp Display Condition Description Priority Color lamp Hand Hand One second Accelerator accelerator accelerator alarm every above 4.75 V 1035 VCM Amber signal out sensor -signal 30 seconds for 5 seconds of range above range Hand...
  • Page 959 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM Function Lamp Alarm Lamp Display Condition Description Priority Color lamp Switch This must closed to Seat not in have a ground with driving Continuous debounce time Amber vehicle in position of less then gear and no 500 ms park brake...
  • Page 960 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM Function Lamp Alarm Lamp Display Condition Description Priority Color lamp Switch One second conditionin closed to conditioning alarm every 1003 VCM Amber g not Vbat for 5 system 30 seconds functional seconds pressure Switch Hydraulic...
  • Page 961 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM Function Lamp Alarm Lamp Display Condition Description Priority Color lamp Brake Brake One second Sender over temperature temperatur alarm every 1000 ohms 1049 VCM Amber sender out of e sensor 30 seconds for 5 seconds range General...
  • Page 962 In this case, a spring is compressed and forces the complete engagement of the pinion as soon as the starter motor starts rotat- ing.
  • Page 963 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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? Charge or replace the battery Check the starter motor wiring.
  • Page 964 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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 in- cludes a 0-20 V voltmeter and a 0-500 A ammeter to detect problems in the starter motor circuit.
  • Page 965 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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 compo- nents of the circuit. IMPORTANT: disconnect the injection pump fuel in- let cut-off wire from the solenoid.
  • Page 966 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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 ........
  • Page 967 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM...
  • Page 968 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 1. Shim 2. Bearing 3. Armature 4. Bearing 5. Coils housing 6. Protection 7. Brush spring 8. Brush assembly 9. Disc 10. Cover 11. Screw 12. Screw 13. Drain 14. Screw 15. Protection 16.
  • Page 969 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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.
  • Page 970 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM Armature Z The surface of the commutator must be clean and without traces of burns. If necessary, remove trac- es of burns using fine sandpaper. Do not use em- ery cloth. Then, clean the commutator with a cloth soaked in gasoline.
  • Page 971 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM FAULT FINDING PROBLEM CAUSE CORRECTION The starter motor does not run Poor battery specific gravity and Inspect the battery. (the magnetic switch makes no level operating noise) Poor ignition switch circuit Replace the wiring harness and the connection or contact ignition switch.
  • Page 972 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 indica- tor lamp remains lighted to indicate the problem.
  • Page 973 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM DIAGRAM OF THE CHARGING CIRCUIT 1. Alternator 6. Battery 2. Output winding of the rotor 7. Key switch 3. Rectifier 8. Charge indicator 4. Regulator 9. Speedometer 5. Starter motor...
  • Page 974 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM COMPONENTS 1. Front housing 16. Sealing ring 2. Rear housing 17. Sealing ring 3. Rectifier 18. Washer 4. Brush holder 19. Screw 5. Regulator 20. Electrical terminal 6. Rear protective 21. Screw 7.
  • Page 975 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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.
  • Page 976 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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.
  • Page 977 (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 cir- cuit and carry out the necessary repairs. Z Connect the terminal L indicator lamp wire to the ground.
  • Page 978 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM CHECKING THE CHARGING CURRENT AND THE REGULATED VOLTAGE Z Make sure that all electrical components are pow- ered 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.
  • Page 979 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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.
  • Page 980 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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).
  • Page 981 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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 re- moving the alternator from the vehicle.
  • Page 982 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM RECTIFIER - CHECKING THE POSITIVE / NEGATIVE DIODES Check each of the six diodes separately by proceed- ing 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.
  • Page 983 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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).
  • Page 984 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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 re- sistance is not infinite, replace the rotor.
  • Page 985 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM FAULT FINDING PROBLEM CAUSE CORRECTION Not recharged Recharge circuit interrupted Check the connections of the (warning lamp, fuse, connector, recharge circuit, clean and tighten etc.). the alternator and battery terminals. Replace the part. Voltage regulator inefficient Replace the part.
  • Page 986 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM BATTERY For the loader backhoe models two different kinds of installation are provided: Z with one battery. Z with two batteries (for cold climates). SPECIFICATIONS Single battery Voltage: ................................12 V Capacity (20 h):............................95 Ah Discharge current:............................900 A Weight with electrolyte: ..........................
  • Page 987 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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 so- lution of diluted sulphuric acid.
  • Page 988 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM Z Remove the battery master switch support (6) with- out 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 bat- tery.
  • Page 989 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM MAINTENANCE SPECIFIC GRAVITY MAINTENANCE The specific gravity of the battery electrolyte indi- cates the state of charge. WARNING Fully charged the specific gravity of the electrolyte is Battery electrolyte causes severe burns. The bat- 1.280 minimum at 25 °C.
  • Page 990 If when charging the battery, violent gassing or charge. This may take 36 hours or more if the bat- spewing of electrolyte occurs, or the battery case tery is heavily discharged. A severely sulphated feels hot (50 °C or greater), reduce or temporarily battery might not accept a charge.
  • Page 991 4. If the specific gravity is 1.280 or more the battery for clogged vents, corrosion, raised vent plugs or a is fully charged and in good operating condition. cracked case. 5. Should the corrected specific gravity be below Test equipment required: 1.280, charge the battery and inspect the charg-...
  • Page 992 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM TEST CHARGING This test is designed only for batteries that have COMMON CAUSES OF BATTERY FAILURES failed the previous capacity test. Z Internal open circuit. 1. Attach the battery starter (high rate discharge Z Internal short circuit.
  • Page 993 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM CONNECTING A BOOSTER BATTERY WARNING When the electrolyte of a battery is frozen, it can ex- plode 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.
  • Page 994 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM COMPONENT TESTING 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.
  • Page 995 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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. GROUND POINTS NOTE: always ensure the ground points are clean and functional.
  • Page 996 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM Ground point D - Fuse board This is also a back-up ground point for Location E. F5/B F5/A F6/C F7/C F8/C F6/B F7/B F8/B F6/A F7/A F8/A F28379 Ground point E - Top right hand B pillar (roof harness) F28380 Ground point F - Operator’seat light...
  • Page 997 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM STARTER SWITCH KEY AND STOP SWITCH NOTE: when the starter switch key/stop switch is turned to ON, the audible alarm sounds until the en- gine is started or the key is returned to the initial po- sition.
  • Page 998 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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.
  • Page 999 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM 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 tem- perature and speed sensor which sends signals back to the EGS.
  • Page 1000 www.maskinisten.net Copyright © SECTION 55 - ELECTRICAL SYSTEM POWERSHIFT SPEED SENSOR TEST Disconnect from control valve and fit the 12 pin con- nector 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).

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