Case T-series TLB En

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Service Manual 580T / 580ST 590ST / 695ST

580T 580ST 590ST 695ST

Backhoe Loaders

Backhoe Loaders Print No. 84428671A

Service Manual

Print No. 84428671A

Copyright ©

TO THE READER This manual has been printed for a skilful engineer to supply necessary technical information to carry out service operations on this machine. Carefully read this manual to collect correct information relevant to repair procedures.

CNH ITALIA S.p.A. Technical Information Viale delle Nazioni, 55 41100 MODENA - Italy

For any question or remark, or in case of any error relevant the contents of this manual, please contact:

REFERENCES Beyond this Service Manual, also refer to the documents listed below: - Operator’s Manual - Service Parts Catalogue

SERVICE MANUAL The Service Manual consists of two volumes: - 580T - 580ST - 590ST - 695ST Service Manual for “Backhoe loader” - 580T - 580ST - 590ST - 695ST Service Manual for “Engine”

The Service Manuals for “Backhoe loader” and “Engine” contain the necessary technical information to carry out service and repair on machine and on engine, necessary tools to carry out those operations and information on service standard, on procedures for connection, disconnection, disassembly and assembly of parts. The Service Manual which covers the backhoe loader models 580T - 580ST - 590ST - 695ST consists of the following volumes, which can be identified through their print number as stated below:

VOLUME

MACHINE TYPE

PRINT NUMBER

Service Manual - “Backhoe loader”

580T - 580ST - 590ST - 695ST

84428671A

Service Manual - “Engine”

580T - 580ST - 590ST - 695ST

87659057A

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PREVENT ACCIDENTS The majority of accidents and injuries which occur in the workshop, at the worksite or on the road, are caused by the failure of some individual to follow simple and fundamental safety rules or precautions. For this reason most accidents can be prevented by recognizing the real cause and taking the necessary precautions, before the accident occurs.

Regardless of the care used in design and construction of any type of equipment, there may be conditions that cannot be completely safeguarded against, without interfering with reasonable accessibility and efficient operation.

A careful operator and / or technician is the best insurance against accidents. The careful observance of this single safety rule would be sufficient to prevent serious injuries:

Never attempt to clean, lubricate or adjust a machine while it is in motion.

WARNING Before carrying out any maintenance operation, adjustment and or repair on machines equipped with attachments, controlled hydraulically or mechanically, make sure that the attachment is lowered and safely set on the ground. If it is necessary to have the equipment partially or fully raised to gain access to certain items, be sure the equipment is suitably supported by means other than the hydraulic lift cylinders, cable and /or mechanical device used for controlling the equipment.

CNH ITALIA S.p.A. Technical Information Viale delle Nazioni, 55 41100 MODENA - Italy

All rights reserved. Reproduction of text or illustrations, in whole or in part, is strictly prohibited.

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BACKHOE LOADER MODELS The complete range of Backhoe Loader models described in this manual are identified below: 580T Powershift

580ST

590ST

695ST

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Powershuttle

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Sideshift stabilizers Center pivot stabilizers

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Rops

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2WD

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/

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Cab

4WD 4WS

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Pilot control Mechanical control Engine Iveco 72 kW - 97 HP model F4GE9484C*601 (mechanical) Engine Iveco 72 kW - 97 HP model F4HE0484G*J102 (electronic)

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Engine Iveco 82 kW - 110 HP model F4HE9484C*J102 (electronic)

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l

Engine Iveco 82 kW - 110 HP (4WS) model F4HE9484C*J103 (electronic)

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Short backhoe dipper

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Long backhoe dipper

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INDEX SECTION 00 - SAFETY RULES FOREWORD..................................................................................................................................................... 4 SAFETY INSTRUCTIONS ................................................................................................................................ 6 PREVENTION OF FIRE OR EXPLOSIONS..................................................................................................... 8 PREVENTION OF BURNS ............................................................................................................................... 9 PRECAUTIONS FOR WASTE DISPOSAL..................................................................................................... 10

SECTION 01 - MAINTENANCE

SECTION 02 - TECHNICAL SPECIFICATIONS MODELS........................................................................................................................................................... 3 IDENTIFICATION OF MAIN COMPONENTS................................................................................................... 4 TECHNICAL SPECIFICATIONS....................................................................................................................... 6 DIESEL ENGINE ......................................................................................................................................... 6 TRANSMISSION.......................................................................................................................................... 9 AXLES ....................................................................................................................................................... 10 BRAKES .................................................................................................................................................... 11 STEERING................................................................................................................................................. 11 HYDRAULIC SYSTEM .............................................................................................................................. 12 FRONT COUNTERWEIGHT ..................................................................................................................... 12 NOISE AND VIBRATION LEVELS ............................................................................................................ 13 BUCKETS .................................................................................................................................................. 13 TYRES ....................................................................................................................................................... 14 DIMENSIONS AND PERFORMANCE............................................................................................................ 15 DIMENSIONS - 2WS SIDESHIFT ............................................................................................................. 15 DIMENSIONS - 4WS SIDESHIFT ............................................................................................................. 16 DIMENSIONS - 4WS CENTER PIVOT...................................................................................................... 17 LOADER ATTACHMENT PERFORMANCE.............................................................................................. 18 PERFORMANCE OF LOADER BUCKET WITH FORKS .......................................................................... 20 BACKHOE ATTACHMENT PERFORMANCE........................................................................................... 21 MAXIMUM LIFTING LOADS........................................................................................................................... 24 LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE .................................................................. 24 BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE ............................................................... 25 SUPPLY SUMMARY TABLE .......................................................................................................................... 26

Copyright © INDEX SECTION 21 - TRANSMISSION POWERSHUTTLE TRANSMISSION ................................................................................................................ 3 TECHNICAL SPECIFICATIONS.................................................................................................................. 4 CONTROLS ................................................................................................................................................. 9 LUBRICATION ........................................................................................................................................... 13 GREASING ................................................................................................................................................ 16 REMOVAL FROM MACHINE .................................................................................................................... 18 DISASSEMBLY AND ASSEMBLY............................................................................................................. 19 TROUBLESHOOTING ............................................................................................................................. 144 REPAIR TIMES........................................................................................................................................ 148 SPECIAL TOOLS..................................................................................................................................... 149 POWERSHIFT TRANSMISSION .................................................................................................................. 150 TECHNICAL SPECIFICATIONS.............................................................................................................. 150 CONTROLS ............................................................................................................................................. 161 LUBRICATION ......................................................................................................................................... 163 GREASING .............................................................................................................................................. 165 REMOVAL FROM MACHINE .................................................................................................................. 166 DISASSEMBLY AND ASSEMBLY........................................................................................................... 167 TROUBLESHOOTING ............................................................................................................................. 331 REPAIR TIMES........................................................................................................................................ 335 SPECIAL TOOLS..................................................................................................................................... 336

SECTION 25 - FRONT AXLE 2WD - 2WS FRONT AXLE................................................................................................................................ 3 TECHNICAL SPECIFICATIONS.................................................................................................................. 3 LUBRICATION AND GREASING ................................................................................................................ 4 REMOVAL FROM MACHINE ...................................................................................................................... 6 DISASSEMBLY AND ASSEMBLY............................................................................................................... 7 TROUBLESHOOTING ................................................................................................................................. 7 4WD - 2WS FRONT AXLE.............................................................................................................................. 10 TECHNICAL SPECIFICATIONS................................................................................................................ 10 LUBRICATION AND GREASING .............................................................................................................. 11 REMOVAL FROM MACHINE .................................................................................................................... 13 DISASSEMBLY AND ASSEMBLY............................................................................................................. 14 TROUBLESHOOTING ............................................................................................................................... 57 SPECIAL TOOLS....................................................................................................................................... 61 4WS FRONT AXLE ......................................................................................................................................... 62 TECHNICAL SPECIFICATIONS................................................................................................................ 62 LUBRICATION AND GREASING .............................................................................................................. 63 REMOVAL FROM MACHINE .................................................................................................................... 65

Copyright © INDEX SECTION 27 - REAR AXLE 2WS REAR AXLE (580T - 580ST).................................................................................................................... 3 TECHNICAL SPECIFICATIONS.................................................................................................................. 3 LUBRICATION AND GREASING ................................................................................................................ 5 REMOVAL FROM MACHINE ...................................................................................................................... 7 DISASSEMBLY AND ASSEMBLY............................................................................................................... 8 TROUBLESHOOTING............................................................................................................................... 61 REPAIR TIMES.......................................................................................................................................... 67 SPECIAL TOOLS....................................................................................................................................... 68 2WS REAR AXLE (590ST) ............................................................................................................................. 69 TECHNICAL SPECIFICATIONS................................................................................................................ 69 LUBRICATION AND GREASING .............................................................................................................. 71 REMOVAL FROM MACHINE .................................................................................................................... 73 DISASSEMBLY AND ASSEMBLY............................................................................................................. 74 TROUBLESHOOTING............................................................................................................................. 127 REPAIR TIMES........................................................................................................................................ 133 SPECIAL TOOLS..................................................................................................................................... 134 4WS REAR AXLE (695ST) ........................................................................................................................... 135 TECHNICAL SPECIFICATIONS.............................................................................................................. 135 LUBRICATION AND GREASING ............................................................................................................ 138 REMOVAL FROM MACHINE .................................................................................................................. 140 DISASSEMBLY AND ASSEMBLY........................................................................................................... 141 TROUBLESHOOTING............................................................................................................................. 219 REPAIR TIMES........................................................................................................................................ 225 SPECIAL TOOLS..................................................................................................................................... 227

SECTION 33 - BRAKE SYSTEM PARKING BRAKE............................................................................................................................................. 3 TECHNICAL SPECIFICATIONS.................................................................................................................. 3 OPERATION................................................................................................................................................ 3 ADJUSTMENT............................................................................................................................................. 4 DISASSEMBLY AND ASSEMBLY............................................................................................................... 5 SERVICE BRAKE ........................................................................................................................................... 14 TECHNICAL SPECIFICATIONS................................................................................................................ 14 OPERATION.............................................................................................................................................. 14

Copyright © INDEX SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC DIAGRAMS ................................................................................................................................. 3 HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS ....................................................... 3 HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS .................................................................... 9 HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS ..................................................... 13 HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS .................................................................. 15 HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS .......................................................... 17 HYDRAULIC PUMP ........................................................................................................................................ 19 HYDRAULIC FIXED-FLOW-RATE GEAR PUMP...................................................................................... 19 HYDRAULIC VARIABLE-FLOW-RATE PISTON PUMP............................................................................ 30 CONTROL VALVES........................................................................................................................................ 44 LOADER CONTROL VALVE ..................................................................................................................... 53 BACKHOE ATTACHMENT CONTROL VALVE......................................................................................... 57 RELIEF VALVES........................................................................................................................................ 69 BACKHOE ATTACHMENT CONTROL VALVE PILOT SOLENOID VALVE .................................................. 78 ACCUMULATOR “GLIDE RIDE” PARKER ..................................................................................................... 81 TECHNICAL SPECIFICATIONS................................................................................................................ 81 MAINTENANCE ......................................................................................................................................... 81 SAFETY ..................................................................................................................................................... 81 CHECKING AND ADJUSTING THE PRECHARGE PRESSURE ............................................................. 82 HYDRAULIC SWING SYSTEM ...................................................................................................................... 84 OPERATION .............................................................................................................................................. 84 HYDRAULIC CYLINDERS.............................................................................................................................. 87 LOADER ATTACHMENT BOOM CYLINDER............................................................................................ 88 LOADER BUCKET CYLINDER.................................................................................................................. 93 4X1 LOADER BUCKET CYLINDER .......................................................................................................... 97 BACKHOE BOOM CYLINDER ................................................................................................................ 100 BACKHOE ATTACHMENT DIPPER CYLINDER .................................................................................... 104 BACKHOE BUCKET CYLINDER............................................................................................................. 108 TELESCOPIC CYLINDER ....................................................................................................................... 112 STABILIZER CYLINDER - CENTER PIVOT (695ST).............................................................................. 115 STABILIZER CYLINDER - SIDESHIFT ................................................................................................... 119 SWING CYLINDER.................................................................................................................................. 123 BACKHOE ATTACHMENT LOCK CYLINDER - SIDESHIFT .................................................................. 127 SPECIAL TOOLS..................................................................................................................................... 128 HYDRAULIC CONTROL LEVERS................................................................................................................ 129 TECHNICAL SPECIFICATIONS.............................................................................................................. 129 CONTROLS AND OPERATION .............................................................................................................. 130 COMPONENTS ....................................................................................................................................... 131 DISASSEMBLY AND ASSEMBLY........................................................................................................... 133 CONTROL LEVER VALVE ...................................................................................................................... 136 TROUBLESHOOTING .................................................................................................................................. 138 PRELIMINARY CHECKS......................................................................................................................... 138 TROUBLESHOOTING (WITH “REXROTH” CONTROL VALVES).......................................................... 139 SWING ..................................................................................................................................................... 141 HYDRAULIC PUMP ................................................................................................................................. 142

Copyright © INDEX SECTION 39 - CHASSIS DESCRIPTION ................................................................................................................................................. 3 REMOVAL AND INSTALLATION OF COMPONENTS .................................................................................... 5 COMPONENTS WITHIN THE CHASSIS .................................................................................................... 5 COMPONENTS OF THE LOWER PART OF THE CHASSIS ..................................................................... 6 COMPONENTS ATTACHED OUTSIDE THE CHASSIS........................................................................... 10 COMPONENTS OF THE UPPER PART ................................................................................................... 11

SECTION 41 - STEERING SYSTEM DESCRIPTION ................................................................................................................................................. 3 2WS STEERING SYSTEM ............................................................................................................................... 4 4WS STEERING SYSTEM ............................................................................................................................... 7 POWER STEERING ....................................................................................................................................... 11 TECHNICAL SPECIFICATIONS................................................................................................................ 11 COMPONENTS ......................................................................................................................................... 13 DISASSEMBLY.......................................................................................................................................... 15 ASSEMBLY................................................................................................................................................ 18

SECTION 50 - CAB HEATING AND AIR CONDITIONING TECHNICAL SPECIFICATIONS....................................................................................................................... 3 GENERAL.................................................................................................................................................... 3 CAB HEATING.................................................................................................................................................. 5 CONTROLS ................................................................................................................................................. 5 OPERATION................................................................................................................................................ 6 AIR FLOW DIFFUSERS .............................................................................................................................. 7 OVERHAUL ................................................................................................................................................. 9 TROUBLESHOOTING............................................................................................................................... 11 AIR CONDITIONING ...................................................................................................................................... 12 PRINCIPLES OF AIR CONDITIONING ..................................................................................................... 12 CONTROLS ............................................................................................................................................... 17 OPERATION.............................................................................................................................................. 18 TROUBLESHOOTING AND TESTING...................................................................................................... 25 FLUSHING THE SYSTEM......................................................................................................................... 43 DRAINING THE SYSTEM ......................................................................................................................... 45 CHARGING THE SYSTEM........................................................................................................................ 46 OVERHAUL ............................................................................................................................................... 47 COMPRESSOR .............................................................................................................................................. 52 TECHNICAL SPECIFICATIONS................................................................................................................ 52 REMOVAL AND INSTALLATION .............................................................................................................. 53 DISASSEMBLY AND ASSEMBLY............................................................................................................. 56 TROUBLESHOOTING............................................................................................................................... 65

Copyright © INDEX SECTION 55 - ELECTRIC SYSTEM ELECTRIC DIAGRAMS .................................................................................................................................... 3 ELECTRIC DIAGRAMS - POWERSHUTTLE ROPS (580T mechanical engine) ........................................ 3 ELECTRIC DIAGRAMS - POWERSHUTTLE CAB (580T mechanical engine) ......................................... 18 ELECTRIC DIAGRAMS - POWERSHUTTLE CAB (580ST - 590ST electronic engine)............................ 36 ELECTRIC DIAGRAMS - POWERSHIFT CAB (2WS) .............................................................................. 54 ELECTRIC DIAGRAMS - POWERSHIFT CAB (4WS) .............................................................................. 73 CONTROLS AND INSTRUMENTS................................................................................................................. 92 FRONT CONTROL PANELS (580T - 580ST - 590ST).............................................................................. 92 FRONT CONTROL PANELS (695ST) ....................................................................................................... 94 CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580T mechanical engine).............................. 96 CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580ST - 590ST - 695ST electronic engine) ..........98 SIDE INSTRUMENT CLUSTER (580T)................................................................................................... 100 SIDE INSTRUMENT CLUSTER (580ST - 590ST - 695ST)..................................................................... 102 ANTI-START SYSTEM ............................................................................................................................ 104 DIAGNOSTIC DISPLAY (580ST - 590ST - 695ST) ...................................................................................... 105 SYMBOLS................................................................................................................................................ 107 SETUP MENU.......................................................................................................................................... 108 PROCEDURE ABOUT SELF TEST......................................................................................................... 109 ON BOARD ERROR CODE RETRIEVAL................................................................................................ 110 BACKLIGHTING AND DIMMING............................................................................................................. 111 WORK HOURS ........................................................................................................................................ 112 OPERATION ............................................................................................................................................ 113 WARNING SYSTEM ................................................................................................................................ 117 MAINTENANCE ....................................................................................................................................... 118 WARNING MESSAGES........................................................................................................................... 119 STARTING SYSTEM .................................................................................................................................... 125 OPERATION ............................................................................................................................................ 125 STARTER MOTOR .................................................................................................................................. 128 TROUBLESHOOTING ............................................................................................................................. 133 ALTERNATOR .............................................................................................................................................. 135 TECHNICAL SPECIFICATIONS.............................................................................................................. 135 OPERATION ............................................................................................................................................ 136 TROUBLESHOOTING ............................................................................................................................. 137 BATTERY...................................................................................................................................................... 138 TECHNICAL SPECIFICATIONS.............................................................................................................. 138 OPERATION ............................................................................................................................................ 138 REPLACEMENT ...................................................................................................................................... 139 CHARGE AND ELECTROLYTE LEVEL CHECK .................................................................................... 140 CONNECTING A BOOSTER BATTERY ................................................................................................. 141 BATTERY MASTER SWITCH ................................................................................................................. 141 TROUBLESHOOTING .................................................................................................................................. 142

Copyright © INDEX SECTION 82 - LOADER ATTACHMENT LOADER ATTACHMENT CONTROLS............................................................................................................. 3 LOADER ATTACHMENT OPERATION ...................................................................................................... 3 4x1 LOADER BUCKET CONTROL (Optional) ............................................................................................ 6 LOADER ATTACHMENT CONTROL LOCK (Specific to certain countries)................................................ 7 BUCKET SELF-LEVELLING............................................................................................................................. 8 LOADER ATTACHMENT SAFETY STRUT...................................................................................................... 9 LOADER ATTACHMENT SAFETY STRUT (2WS) ..................................................................................... 9 LOADER ATTACHMENT SAFETY STRUT (4WS) ................................................................................... 10 REMOVAL AND INSTALLATION OF LOADER BUCKET.............................................................................. 11 STANDARD LOADER BUCKET................................................................................................................ 11 LOADER BUCKET WITH FORKS (Optional) ............................................................................................ 12 BUCKET TEETH REPLACEMENT............................................................................................................ 13 LOADER REMOVAL....................................................................................................................................... 14

SECTION 84 - BACKHOE ATTACHMENT DESCRIPTION AND OPERATION................................................................................................................... 3 BACKHOE ATTACHMENT CONTROLS .......................................................................................................... 6 BACKHOE ATTACHMENT MECHANICAL CONTROLS ............................................................................ 7 BACKHOE ATTACHMENT HYDRAULIC CONTROLS ............................................................................. 18 BACKHOE ATTACHMENT SIDESHIFT (Sideshift version) ...................................................................... 24 BACKHOE ATTACHMENT DISASSEMBLY .................................................................................................. 26 BACKHOE BUCKET REPLACEMENT...................................................................................................... 28 BACKHOE BUCKET.................................................................................................................................. 29 BACKHOE ATTACHMENT HYDRAULIC HANDLING ................................................................................... 30 CONTROLS ............................................................................................................................................... 30 HYDRAULIC DIAGRAM ............................................................................................................................ 31 DISASSEMBLY AND ASSEMBLY............................................................................................................. 32

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580T 580ST 590ST 695ST

SECTION 00 - SAFETY RULES

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Copyright © SECTION 00 - SAFETY RULES

SAFETY INSTRUCTIONS WARNING This warning symbol points out important messages involving your safety. Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and to safeguard your safety and personal integrity. In this manual you will find this symbol together with the following keywords:

WARNING This symbol warns about the possibility of potential damages to the machine that can involve the operator’s safety.

WARNING With specific warnings about potential dangers for the operator’s or other persons integrity directly or indirectly involved. The non-compliance with the warnings preceded by the above-mentioned keywords (WARNING and DANGER) can cause serious accidents or even the death of the persons involved. Moreover, in the present Manual, some instructions are given with text in italics, preceded by the words NOTE and CAUTION. NOTE: it emphasizes and underlines to the operator the correct technique or correct procedure to follow.

WARNING This symbol warns about the possibility of potential damages to the machine that can involve the operator’s safety.

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FOREWORD Backhoe loaders 580T - 580ST - 590ST - 695ST have been designed to perform most earth-moving operations. If you use this machine for duties involving the use of attachments, accessories, or special tools, consult your Dealer to make sure that the adaptations or modifications carried out are in conformity with the machine’s technical specifications and with current regulations on safety. Any modifications or adaptations which are not approved by the manufacturer may invalidate the machine’s original conformity with safety requirements. The machine must be used according to its intended use, respecting the safety and precautionary rules and strictly following the operating instructions. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately.

DANGER A different use of the excavator or of its working equipment: - for lifting or transporting persons; - as a working platform; - for lifting loads without the attachment being approved for this purpose; - for pulling loads; - is considered unintended use. Unintended use may cause injury or life-threatening risks for the operator and for other persons. The manufacturer/supplier cannot be held responsible for any damage resulting from unintended use. The risk involved in such misuse lies entirely with the user.

DANGER It is absolutely forbidden to tamper with and/or change the setting of any of the hydraulic system valves to avoid damaging machine components, with a consequent risk for personal safety. The current Operator’s Manual is the user’s guide for correct run-in, use and maintenance of the machine.

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Copyright © SECTION 00 - SAFETY RULES Carefully read this Operator’s Manual and store it in the cab for quick location and reference. Instructions concerning safety, operation and maintenance have been developed to permit safe service and repair of this machine without any risk. In the event of queries or suggestions relevant to your machine do not hesitate to address to your Dealer. Dealers have qualified and trained personnel at disposal as well as Original Spares, means and equipment suitable to carry out all necessary maintenance. Any modifications or adaptations which are not approved by the manufacturer may invalidate the machine’s original conformity with safety requirements. IMPORTANT: the engine and fuel system on your machine are designed and built to government emissions standards. Tampering by dealers, customers, operators and users is strictly prohibited by law. Failure to comply with this prohibition could result in government fines, rework charges, invalid warranty, legal action and possible confiscation of the machine until rework to original condition is completed. Engine service and/or repairs must be carried out by a certified technician only. NOTE: each machine is supplied complete with a copy of this Manual. Descriptions and illustrations provided herein are not binding. The Manufacturer, provided that the basic characteristics of machine types described and shown in this Manual remain the same, reserves the right to change components, parts and accessories supplied without any commitment to timely update this publication; and this any time it deems it convenient for improvement purposes or due to commercial or manufacturing requirements. For exact information, please consult your Dealer or contact the Manufacturer’s Branch Offices, who remain at your disposal for further help.

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SPARE PARTS The “non-genuine” spare parts have not been checked and authorized by the Manufacturer. The assembly and/or use of such products may have negative effects on the machine design features and could impair its operation safety. The Manufacturer is not liable for any damage caused by “non-genuine” spare parts or accessories.

WARRANTY This machine is under warranty according to the regulations in force in Your Country and in compliance with the sales agreement drawn up with the Dealer. The warranty, however, expires if the operation and maintenance instruction for this machine and contained in this manual, have not been followed.

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SAFETY INSTRUCTIONS Carefully read the safety rules contained herein and follow advised precautions to avoid potential hazards and to safeguard your safety and personal integrity. Your safety and that of the people around you depends on you. It is essential that you understand this manual for a correct inspection, lubrication and repair of this machine. Read this manual carefully and check that: - you understand fully the symbols on the controls and the safety signs used in this manual and on the machine; - you understand fully the speed, stability, braking and steering characteristics of the machine. If you are in any doubt, consult your Dealer. The safety messages in this section concern situations which may arise during normal machine operation, servicing and repair. These safety messages also indicate the different ways of coping with these situations. Other safety messages are used throughout the manual to indicate specific dangers. The information given in this chapter is a summary of the basic rules to respect at all times and does not exempt you from observing traffic regulations or the requirements of insurance companies. The presence of grease, oil, mud or (in winter) ice on the steps and access handles can cause accidents. Make sure they are always clean. When mounting or dismounting from the machine always face the machine and use the steps and access handles on the left-hand side of the machine.

Copyright © SECTION 00 - SAFETY RULES Wear close fitting clothing and safety equipment appropriate for the job: - safety helmet; - safety shoes; - heavy gloves; - reflective clothing; - wet weather clothing. If the environment conditions make it necessary, the following personal safety equipment should be at hand: - respirators (or dustproof masks); - ear plugs or acoustic ears protections; - goggles with lateral shield or masks for eyes protection. Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get caught into moving parts. Any functional disorders, especially those affecting the safety of the machine, should therefore be rectified immediately. Make sure that you fully understand the symbols of the safety decals applied on the machine. Make sure that they are always clean and perfectly legible. Be prepared for emergencies. Always keep a first aid kit and a fire extinguisher close at hand on the machine. Make sure that the fire extinguisher is serviced in accordance with the manufacturer’s instructions.

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PREVENTION OF FIRE OR EXPLOSIONS The engine fuel can originate an explosion or a fire. Never refuel when the engine is running. Do not smoke during refuelling. Take all the necessary safety measures when welding, grinding or when working near a naked flame. Use a non-inflammable product for cleaning parts.

A spark or a flame can cause the electrolyte of the battery to explode. To prevent any risk of explosion, observe the following instructions: - when disconnecting the battery cables, always disconnect the negative (-) cable first; - to reconnect the battery cables, always connect the negative (-) cable last; - never short-circuit the battery clamps with metal objects; - do not weld, grind or smoke near a battery. The engine exhaust may produce sparks. Before using the machine in an area which may contain inflammable vapours, ensure that there is good ventilation. Always keep a fire extinguisher available on the machine. Make sure that it is properly maintained in conformity with the manufacturer’s instructions.

Copyright © SECTION 00 - SAFETY RULES

PREVENTION OF BURNS The battery electrolyte generates severe burns. The battery contains sulphuric acid. Avoid any contact with the skin, eyes or clothing. Antidote: - EXTERNAL: rinse well with water, removing any soiled clothing. - INTERNAL: avoid vomiting. Drink water to rinse your mouth. Consult a doctor. - EYES: rinse thoroughly with water for 15 minutes and get prompt medical attention. When the electrolyte of a battery is frozen, it can explode if you attempt to charge the battery or if you try to start the engine using a booster battery. Always keep the battery charged to prevent the electrolyte freezing. Batteries generate explosive gases. Keep all flames, sparks and cigarettes away. Provide good ventilation when changing a battery or using a battery in an enclosed space. Always protect your eyes when working near a battery. Never touch the battery terminals with your hands. This can induce a state of electrolysis and impair the main organs of the body.

Hot coolant could spray out if the radiator cap is removed while the system is still hot. To remove the cap: allow the system to cool down, turn the cap to the first notch and wait until there is no more pressure. Then remove the cap.

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PRECAUTIONS FOR WASTE DISPOSAL Improperly disposing of waste can threaten the environment. Each country has its own Regulations on this subject. It is therefore advisable to prepare suitable containers to collect and store momentarily all solid and fluid materials that must not be scattered in the environment to avoid pollution. At preset intervals these products will be delivered to disposal stations legally recognized and present in this Country. Here below is a list of the products in the machine which require disposal: - hydraulic oil; - brake system oil; - coolant mixture, condensation residue and pure anti-freeze; - diesel oil; - oil and diesel oil filter elements; - engine and air conditioning air filter elements; - battery. Also polluting rags, paper, sawdust and gloves must be disposed in compliance with the same procedures. Do not use food or beverage containers that may mislead someone into drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Air conditioning coolant escaping into the air can damage the Earth’s atmosphere. Government regulations may require a certified air conditioning service centre to recover and recycle used air conditioning coolant. Obtain information on the proper way to recycle or dispose of waste from your local environmental or recycling centre, or from your Dealer.

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580T 580ST 590ST 695ST


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Copyright © SECTION 01 - MAINTENANCE Do not carry out any service operation until you have read and understood the instructions and warnings given in this manual. Observe the adjusting, maintenance and inspection activities and intervals set out in the operating instructions, including information on the replacement of parts and equipment as this service concerns exclusively the qualified personnel. Wear safety equipment and suitable clothing to perform maintenance operations on the machine. During maintenance operations, apply a warning plate. Always wear eye protection when using a tool which might project metal particles. Use a hammer with a soft face, such as copper, for pin assembly. Incorrectly performed maintenance or adjustments can cause serious injury. If you do not understand a maintenance or adjustment procedure, consult your Dealer. Before performing any maintenance operation on this machine, make sure it is in a safety condition.

Move the machine to a level and firm ground, away from any soft ground, excavations and poorly shored cavity. Rest the loader attachment on the ground if no maintenance operation is to be performed on it. Otherwise, raise the attachment and block the support strut. Place the backhoe attachment in road travel position if no maintenance operation is to be performed on it. Otherwise, rest it on the ground. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Completely raise the stabilizers and lock them mechanically. Stop the engine and remove the starter key. Open the oil tank plug. Release the hydraulic pressure by operating the control levers in all directions. On hydraulically controlled machines, turn the key to ON and release the pressure by moving the hydraulic control levers in all directions. Disconnect the electric system by disconnecting the battery master switch.

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Place some wedges under the wheels so as to prevent the machine from moving. Unauthorized modifications of the machine can cause serious injuries. Do not carry out any modification on this machine without obtaining prior authorization from your Dealer. Any modification carried out must be in conformity with the machine’s technical specifications and must conform to current safety regulations. Do not carry out any welding operation on the machine without prior authorization from your Dealer. Some of the machine’s components are subject to type approvals. It is mandatory when replacing those components to ensure that they are in conformity with regulations. Hydraulic fluid or grease under pressure which penetrates the skin can cause serious injury. Take the necessary safety precautions (protective clothing and face and hand protection) to prevent all such risks. In addition, before handling these products, read the manufacturer’s specific instructions for their use. If hydraulic fluid penetrates the skin a doctor must be called immediately. When carrying out a welding operation on the machine, as authorized by the manufacturer and in accordance with his specifications, disconnect the electric system by means of the battery master switch, connect the welding set earth lead to the component on which the welding is to be carried out (never connect the ground lead to a hydraulic system component) and disconnect the electric cables of the motor control unit (in case of electronic motors). A burst tyre can cause serious injury. Regularly check the condition of tyres and always observe the inflation pressures defined in accordance with the type of tyre and ground conditions.

Copyright © SECTION 01 - MAINTENANCE When checking the tyre pressure or during an inflation operation, never stay in front of the tyre but always keep to the tread side. Always use an inflation cage when the wheel is removed from the machine. Keep all other persons away from the area. Never weld near a tyre. It is essential to remove the tyre before any welding operation. Take the necessary safety measures to protect your face when using compressed air. The machine’s structure is in conformity with the FOPS and ROPS protection standards. Any modification (drilling, welding, etc.) may cause that conformity to be invalidated.

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Copyright ©

580T 580ST 590ST 695ST

SECTION 02 - TECHNICAL SPECIFICATIONS MODELS........................................................................................................................................................... 3 IDENTIFICATION OF MAIN COMPONENTS................................................................................................... 4 TECHNICAL SPECIFICATIONS....................................................................................................................... 6 DIESEL ENGINE ......................................................................................................................................... 6 TRANSMISSION.......................................................................................................................................... 9 AXLES ....................................................................................................................................................... 10 BRAKES .................................................................................................................................................... 11 STEERING................................................................................................................................................. 11 HYDRAULIC SYSTEM .............................................................................................................................. 12 FRONT COUNTERWEIGHT ..................................................................................................................... 12 NOISE AND VIBRATION LEVELS ............................................................................................................ 13 BUCKETS .................................................................................................................................................. 13 TYRES ....................................................................................................................................................... 14 DIMENSIONS AND PERFORMANCE............................................................................................................ 15 DIMENSIONS - 2WS SIDESHIFT ............................................................................................................. 15 DIMENSIONS - 4WS SIDESHIFT ............................................................................................................. 16 DIMENSIONS - 4WS CENTER PIVOT...................................................................................................... 17 LOADER ATTACHMENT PERFORMANCE.............................................................................................. 18 PERFORMANCE OF LOADER BUCKET WITH FORKS .......................................................................... 20 BACKHOE ATTACHMENT PERFORMANCE........................................................................................... 21 MAXIMUM LIFTING LOADS........................................................................................................................... 24 LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE .................................................................. 24 BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE ............................................................... 25 SUPPLY SUMMARY TABLE .......................................................................................................................... 26

Copyright © 2

1.

SECTION 02 - TECHNICAL SPECIFICATIONS

Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS

3

MODELS 580T Powershift

580ST

590ST

695ST

/

Powershuttle

/

Stabilizer sideshift Stabilizer center pivot

/

/

/

Rops

/

/

/

2WD

/

/

/

/

/

/

/

/

/

/ /

Cab

4WD 4WS

/

Pilot control Mechanical control Engine Iveco 72 kW - 97 HP model F4GE9484C*601 (mechanical) Engine Iveco 72 kW - 97 HP model F4HE0484G*J102 (electronic)

/

Engine Iveco 82 kW - 110 HP model F4HE9484C*J102 (electronic)

/

/

l

Engine Iveco 82 kW - 110 HP (4WS) model F4HE9484C*J103 (electronic)

/

/

/

Short backhoe dipper

/

/

/

Long backhoe dipper

/

Copyright © 4


IDENTIFICATION OF MAIN COMPONENTS 2WS

1. Loader bucket 2. Loader attachment

9. Dipper / telescopic dipper of backhoe attachment

3. Front axle

10. Backhoe bucket

4. Fuel tank

11. Backhoe attachment sideshift carriage

5. Rear axle

12. Stabilizers

6. Cab

13. Battery box

7. Engine guard

14. Hydraulic oil tank

8. Backhoe attachment boom

Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS 4WS

1. Loader bucket 2. Loader attachment

9. Dipper / telescopic dipper of backhoe attachment

3. Front axle

10. Backhoe bucket

4. Fuel tank

11. Backhoe attachment sideshift carriage

5. Rear axle

12. Stabilizers

6. Cab

13. Battery box

7. Engine guard

14. Hydraulic oil tank

8. Backhoe attachment boom

5

Copyright © 6


TECHNICAL SPECIFICATIONS DIESEL ENGINE 72 kW - 97 HP ENGINE (580T) Specifications (EEC 88/195) .................................................................................. 72 kW - 97 HP @ 2200 rpm Model ...................................................................................................................................... F4GE9484C*601 Type ......................................................................................................................................diesel, mechanical No. of cylinders ................................................................................................................................................ 4 Valves per cylinder ........................................................................................................................................... 2 Bore.............................................................................................................................................. 104 mm (4 in) Stroke ........................................................................................................................................ 132 mm (5.2 in) Displacement .................................................................................................................. 4485 cm3 (237.69 in3) Compression ratio .................................................................................................................................... 17.5:1 Maximum torque (EC) ......................................................................................420 Nm (309 lbf·ft) @ 1250 rpm Low idle speed at no load ........................................................................................................... 1000 ± 50 rpm High idle speed at no load (engine not installed) ........................................................................ 2430 ± 50 rpm High idle speed at no load (engine not installed on the vehicle) ................................................. 2380 ± 60 rpm Maximum speed at full load ................................................................................................................ 2200 rpm Air intake ....................................................................................................TAA (turbocharged with aftercooler)

Supply Type ............................................................................................................................................ direct injection Injection pump ............................................................................................. BOSCH ROTARY VE 4/12 F1100L Injection sequence ..................................................................................................................................1-3-4-2 Cold-start device .............................................................................................................“grid heater” (optional)

Cooling Pump type ......................................................................................................................................... H2O pump Pump drive ...........................................................................................................................................belt drive Temperature switch (opening start) .......................................................................... 81 ± 2 °C (177.8 ± 35.6 °F)


7

72 kW - 97 HP ENGINE (580ST) Specifications (EEC 88/195) .................................................................................. 72 kW - 97 HP @ 2200 rpm Model .................................................................................................................................... F4HE0484G*J102 Type .........................................................................................................................................diesel, electronic No. of cylinders ................................................................................................................................................ 4 Valves per cylinder ........................................................................................................................................... 4 Bore ............................................................................................................................................. 104 mm (4 in) Stroke........................................................................................................................................ 132 mm (5.2 in) Displacement .................................................................................................................. 4485 cm3 (237.69 in3) Compression ratio.................................................................................................................................... 17.5:1 Maximum torque (EC) ...................................................................................... 453 Nm (334 lbf·ft) @ 1400 rpm Low idle speed at no load ........................................................................................................... 1000 ± 50 rpm High idle speed at no load (engine not installed) ........................................................................ 2430 ± 50 rpm High idle speed at no load (engine not installed on the vehicle) ................................................. 2380 ± 60 rpm Maximum speed at full load ................................................................................................................ 2200 rpm Air intake ....................................................................................................TAA (turbocharged with aftercooler)

Supply Type ........................................................................................................................high-pressure, common rail Injection pump............................................................................................................ CP3 high-pressure pump Control unit................................................................................................................................................EDC7 Injection sequence ..................................................................................................................................1-3-4-2 Cold-start device .............................................................................................................“grid heater” (optional)

Cooling Pump type ......................................................................................................................................... H2O pump Pump drive ...........................................................................................................................................belt drive Temperature switch (opening start)......................................................................... 81 ± 2 °C (177.8 ± 35.6 °F)

Copyright © 8


82 kW - 110 HP ENGINE (590ST / 695ST) Specifications (EEC 88/195) ................................................................................. 82 kW - 110 HP @ 2200 rpm Model (590ST) ....................................................................................................................... F4HE9484C*J102 Model (695ST) ....................................................................................................................... F4HE9484C*J103 Type ......................................................................................................................................... diesel, electronic No. of cylinders ................................................................................................................................................. 4 Valves per cylinder ............................................................................................................................................ 4 Bore............................................................................................................................................... 104 mm (4 in) Stroke ......................................................................................................................................... 132 mm (5.2 in) Displacement ................................................................................................................... 4485 cm3 (237.69 in3) Compression ratio ..................................................................................................................................... 17.5:1 Maximum torque (EC) ..................................................................................516 Nm (380.58 lbf·ft) @ 1400 rpm Low idle speed at no load ............................................................................................................ 1000 ± 50 rpm High idle speed at no load (engine not installed) ......................................................................... 2430 ± 50 rpm High idle speed at no load (engine not installed on the vehicle) .................................................. 2380 ± 60 rpm Maximum speed at full load ................................................................................................................. 2200 rpm Air intake .....................................................................................................TAA (turbocharged with aftercooler)

Supply Type .........................................................................................................................high-pressure, common rail Injection pump ............................................................................................................. CP3 high-pressure pump Control unit.................................................................................................................................................EDC7 Injection sequence ...................................................................................................................................1-3-4-2 Cold-start device ..............................................................................................................“grid heater” (optional)

Cooling Pump type .......................................................................................................................................... H2O pump Pump drive ............................................................................................................................................belt drive Temperature switch (opening start) .......................................................................... 81 ± 2 °C (177.8 ± 35.6 °F)


9

TRANSMISSION 2WD/2WS TRANSMISSION - POWERSHUTTLE (580T) Model ..................................................................................................................... CARRARO TLB1 MPB 2WD Type (4x4) ..................................................................................................4 forward and 4 reverse travel gears Torque converter ratio .................................................................................................................................. 2.38 Transmission ratios: 1st gear ......................................................................... forward travel 5.603:1

reverse travel 4.643:1

2nd gear........................................................................forward travel 3.481:1


3rd gear ........................................................................forward travel 1.585:1


4th gear......................................................................... forward travel 0.793:1


4WD/2WS TRANSMISSION - POWERSHUTTLE (580ST - 590ST) Model ..................................................................................................................... CARRARO TLB1 MPB 4WD Type (4x4) ..................................................................................................4 forward and 4 reverse travel gears Torque converter ratio .................................................................................................................................. 2.38 Transmission ratios: 1st gear ......................................................................... forward travel 5.603:1








4WD/2WS TRANSMISSION - POWERSHIFT (580ST - 590ST) Model ..................................................................................................................... CARRARO TLB2 MPB 4WD Type (4x4) ..................................................................................................4 forward and 4 reverse travel gears Torque converter ratio .................................................................................................................................. 2.38 Transmission ratios: 1st gear ......................................................................... forward travel 5.533:1








4WD/4WS TRANSMISSION - POWERSHIFT (695ST) Model ..................................................................................................................... CARRARO TLB2 MPB 4WS Type (4x4) ..................................................................................................4 forward and 4 reverse travel gears Torque converter ratio .................................................................................................................................. 2.38 Transmission ratios: 1st gear ......................................................................... forward travel 4.468:1








Copyright © 10


AXLES FRONT AXLES 2WD/2WS front axle (580T) Model .......................................................................................................................................................... CNH Type ....................................................................................................................................................... steering 4WD/2WS front axle (580ST - 590ST) Model .......................................................................................................................................................... CNH Type ....................................................................................................................................................... steering 4WD/4WS front axle (695ST) Model ...................................................................................................................................... CARRARO 26.32 Type ....................................................................................................................................................... steering REAR AXLES 2WS rear axle Model (580T - 580ST) ............................................................................................................. CARRARO 28.44 Model (590ST) ........................................................................................................................ CARRARO 28.50 Type ............................................................................................................................................................. rigid 4WS rear axle (695ST) Model ................................................................................................................................... CARRARO 26.32M Type ....................................................................................................................................................... steering Differential lock......................................................................................................................................... electric


11

BRAKES SERVICE BRAKES 2WS Type .......................................................................................................wet multi-discs, 4 x axle (2 x half axle) Braking surface ..................................................................................................................... 1236 cm2 (191 in2) 4WS Type .......................................................................................................wet multi-discs, 6 x axle (3 x half axle) Braking surface .................................................................................................................... 1092 cm2 (169 in2) PARKING BRAKE Type ....................................................................................................................................... manual, with lever Maximum lever pull ....................................................................................................................1650 N (371 lbf) Lever stroke ............................................................................................................................... 21 mm (0.87 in) Maximum torque - POWERSHUTTLE ...............................................................................2000 Nm (1475 lbf·ft) Maximum torque - POWERSHIFT ..................................................................................... 1500 Nm (1106 lbf·ft)

STEERING 2WS ............................................................................................................................................... 2 wheel steer 4WS ............................................................................................................................................... 4 wheel steer System pressure .............................................................................................. 170 ÷ 175 bar (2465 ÷ 2538 psi) POWER STEERING 2WS (with variable-flow-rate pump) Model ......................................................................................................................... EATON P/N 403 -8754-04 Displacement ............................................................................................................. 160 cm3/rev (9.76 in3/rev) Shock valve adjustment ......................................................................................................... 235 bar (3408 psi) Load-sensing pressure relief valve adjustment...................................................................... 175 bar (2538 psi) 2WS (with gear pump) Model ......................................................................................................................... EATON P/N 403 -8754-08 Displacement ............................................................................................................. 160 cm3/rev (9.76 in3/rev) Shock valve adjustment ......................................................................................................... 235 bar (3408 psi) Load-sensing pressure relief valve adjustment............................................................................................... No 4WS Model ......................................................................................................................... EATON P/N 403 -7754-04 Displacement ............................................................................................................. 160 cm3/rev (9.76 in3/rev) Shock valve adjustment ......................................................................................................... 235 bar (3408 psi) Load-sensing pressure relief valve adjustment...................................................................... 175 bar (2538 psi)

Copyright © 12


HYDRAULIC SYSTEM GEAR PUMP Pump 72 kW - 97 HP (580T - 580ST) Model ...........................................................................................................CASAPPA KP 30.34 - 05 S6 - LMF Type ....................................................................................................................................... double gear pump Flow rate ..................................................................................... 35.427 + 35.427 cm3/rev (2.16 + 2.16 in3/rev) Pump 82 kW - 110 HP (590ST - 695ST) Model ...........................................................................................................CASAPPA KP 30.38 - 05 S6 - LMF Type ....................................................................................................................................... double gear pump Flow rate ..................................................................................... 40.258 + 35.427 cm3/rev (2.45 + 2.16 in3/rev) VARIABLE-FLOW-RATE PUMP Pump 72 kW - 97 HP (580ST) Model ....................................................................................................................... DANFOSS J71C Series 45 Type ......................................................................................................................................... with axial pistons Flow rate ...................................................................................................................... 71 cm3/rev (4.33 in3/rev) Pump 82 kW - 110 HP (590ST - 695ST) Model ....................................................................................................................... DANFOSS J75C Series 45 Type ......................................................................................................................................... with axial pistons Flow rate ...................................................................................................................... 75 cm3/rev (4.57 in3/rev)

FRONT COUNTERWEIGHT COUNTERWEIGHT - 2WS Standard ...................................................................................................................................... 159 kg (350 lb) Medium ....................................................................................................................................... 330 kg (727 lb) COUNTERWEIGHT - 4WS Standard ...................................................................................................................................... 160 kg (352 lb)


13

NOISE AND VIBRATION LEVELS NOISE LEVEL Certified by the Manufacturer. In compliance with European Directive 2000/14/EC - Stage II. Internal noise level (LpA) ........................................................................................................................... 77 db External noise level (LwA) (580T - 580ST) .............................................................................................. 102 db External noise level (LwA) (590ST - 695ST)............................................................................................ 103 db VIBRATION LEVEL INSIDE THE CAB Upper limbs ................................................................................................ level lower than 2.5 m/s2 (8.20 ft/s2) Abdomen.................................................................................................... level lower than 0.5 m/s2 (1.64 ft/s2)

BUCKETS LOADER BUCKETS 2WS

4WS

Type

1 m3 (35.3 ft3) standard

4x1

6x1 (with forks)

Heaped capacity

1.0 m3 (35.3 ft3)

1.0 m3 (35.3 ft3)

1.0 m3 (35.3 ft3)

Width

2250 mm (88.58 in)

2250 mm (88.58 in)

2250 mm (88.58 in)

Weight

410 kg (902 lb)

800 kg (1760 lb)

960 kg (2112 lb)

Heaped capacity

1.15 m3 (40.61 ft3)

1.15 m3 (40.61 ft3)

1.15 m3 (40.61 ft3)

Width

2400 mm (94.4 in)

2400 mm (94.4 in)

2400 mm (94.4 in)

Weight

426 kg (937 lb)

830 kg (1826 lb)

990 kg (2178 lb)

BACKHOE BUCKETS Type

Width [mm (in)]

Weight [kg (lb)]

300 (11.81)

89 (196)

400 (15.75)

104 (229)

450 (17.71)

112 (247)

600 (23.62)

130 (286)

750 (29.53)

151 (333)

900 (35.43)

171 (377)

406 (15.98)

139 (306)

457 (17.9)

149 (328)

610 (24)

176 (388)

914 (35.9)

228 (503)

Normal operation

Heavy Duty

Copyright © 14


TYRES TYRE TYPES Tyres - 2WS Front tyres

Rear tyres

11L-16 F3 12PR

18.4-26 R4 12PR

11L-16 F3 12PR

16.9-28 R4 12PR

12.5/80 - 18 L3 10PR

18.4-26 R4 10PR

12.5/80 - 18 L3 10PR

16.9-28 R4 10PR

320/80 R18 IT 520

480/80 R26 IT520

2WD

4WD

Tyres - 4WS Front and rear tyres 16.9/24 R4 12PR 16.9/28 R4 12PR 440/80 R28 IT520 440/80 R28 IT530

NUT TORQUES Front nuts (2WS) ....................................................................................................................330 Nm (243 lbf·ft) Rear nuts (2WS) ....................................................................................................................540 Nm (398 lbf·ft) Front and rear nuts (4WS) .....................................................................................................700 Nm (516 lbf·ft)


15

DIMENSIONS AND PERFORMANCE DIMENSIONS - 2WS SIDESHIFT

Front tyres ..................................................................................................................................... 12.5/80-18 I3 Rear tyres ..........................................................................................................................................18.4-26 R4 Standard loader bucket ................................................................................................................. 1 m3 (35.3 ft3) Standard backhoe bucket ...................................................................................................... 914 mm (35.98 in) A

Overall machine length

5865 mm (230.90 in)

B

Loader bucket reach

2060 mm (81.10 in)

C

Wheel base

2175 mm (85.62 in)

D

Backhoe bucket dimensions

1630 mm (64.17 in)

E

Rear wheel base - backhoe attachment swing axis

1325 mm (52.16 in)

F

Machine maximum height (upper part of backhoe attachment boom)

3680 mm (144.88 in)

G

Stabilizer width

2430 mm (95.66 in)

H

Cab height

2950 mm (116.14 in)

I

Loader bucket width

2250 mm (88.58 in)

Copyright © 16


DIMENSIONS - 4WS SIDESHIFT

Front and rear tyres................................................................................................................ 440/80-R28 IT530 Standard loader bucket .......................................................................................................... 1.15 m3 (40.61 ft3) Standard backhoe bucket....................................................................................................... 914 mm (35.98 in) A


5785 mm (227.76 in)

B

Loader bucket reach

1975 mm (77.75 in)

C

Wheel base

2200 mm (86.61 in)

D


1630 mm (64.17 in)

E


1325 mm (52.16 in)

F

Machine maximum height (upper part of backhoe attachment boom)

3650 mm (143.70 in)

G

Stabilizer width

2480 mm (97.63 in)

H

Cab height

2900 mm (114.17 in)

I

Loader bucket width

2400 mm (94.48 in)


17

DIMENSIONS - 4WS CENTER PIVOT

Front and rear tyres ...............................................................................................................440/80 R28 IT530 Standard loader bucket .......................................................................................................... 1.15 m3 (40.61 ft3) Standard backhoe bucket ...................................................................................................... 914 mm (35.98 in) A


7295 mm (287.20 in)

B

Loader bucket reach

1975 mm (77.75 in)

C

Wheel base

2200 mm (86.61 in)

D


3120 mm (122.83 in)

E


1325 mm (52.16 in)

F

Machine maximum height (with standard dipper)

3712 mm (146.14 in)

G

Standard stabilizer width - reversible

2380 mm - 2580 mm (93.70 in - 101.57 in)

H

Cab height

2900 mm (114.17 in)

I

Loader bucket width

2400 mm (94.48 in)

Copyright © 18


LOADER ATTACHMENT PERFORMANCE 580T - 580ST - 590ST

Front tyres ..................................................................................................................................... 12.5/80-18 I3 Rear tyres.......................................................................................................................................... 18.4-26 R4 Standard loader bucket .................................................................................................................1 m3 (35.3 ft3) A

Maximum height/dimensions

4255 mm (167.52 in)

B

Maximum height of loader bucket pin/pivot

3460 mm (136.22 in)

C

Maximum dumping height

D

Digging depth

120 mm (4.72 in)

E

Loader attachment reach when raised in dumping position (according to front counterweight)

830 mm (32.68 in)

2625 mm (103.35)

Angle of lowered closed bucket

45°

Dumping angle

45°


19

695ST

Front and rear tyres ...............................................................................................................440/80 R28 IT530 Standard loader bucket .......................................................................................................... 1.15 m3 (40.61 ft3) A

Maximum height/dimensions

4350 mm (171.26 in)

B

Maximum height of loader bucket pin/pivot

3490 mm (137.40 in)

C

Maximum dumping height

2715 mm (106.89 in)

D

Digging depth

E

Loader attachment reach when raised in dumping position (according to front counterweight)

113 mm (4.44 in) 745 mm (29.33 in)


45°

Dumping angle

45°

Copyright © 20


PERFORMANCE OF LOADER BUCKET WITH FORKS 580T - 580ST - 590ST

A

Maximum height of loader bucket pin/pivot with lifted forks

4245 mm (167.13 in)

B

Fork maximum height

3460 mm (136.22 in)

C

Height of loader bucket pin/pivot of loader bucket with lowered forks

D

Fork reach when raised

2320 mm (91.34 in)

E

Fork reach when lowered

3185 mm (125.39 in)

A

Maximum height of loader bucket pin/pivot with lifted forks

3520 mm (138.58 in)

B

Fork maximum height

3060 mm (120.47 in)

C

Height of loader bucket pin/pivot of loader bucket with lowered forks

D

Fork reach when raised

2195 mm (86.42 in)

E

Fork reach when lowered

3185 mm (125.39 in)

460 mm (18.11 in)

695ST

460 mm (18.11 in)


21

BACKHOE ATTACHMENT PERFORMANCE 580T - 580ST - 590ST

Front tyres ..................................................................................................................................... 12.5/80-18 I3 Rear tyres ..........................................................................................................................................18.4-26 R4 Standard backhoe bucket ...................................................................................................... 314 mm (12.36 in) Standard dipper

Telescopic dipper extended

A

Maximum digging height

5875 mm (231.30 in)

6790 mm (267.32 in)

B

Maximum height at full load

3925 mm (154.53 in)

4835 mm (190.35 in)

C

Maximum digging depth

4370 mm (172.05 in)

5435 mm (213.98 in)

D

Maximum digging reach with lowered bucket

5230 mm (205.90 in)

6240 mm (245.67 in)

E

Maximum reach when loaded

870 mm (34.25 in)

1425 mm (56.10 in)

200°

195°

Bucket digging angle

Copyright © 22


695ST SIDESHIFT

Front and rear tyres ............................................................................................................... 440/80 R28 IT530 Standard backhoe bucket....................................................................................................... 914 mm (35.98 in) Standard dipper


A


6190 mm (243.70 in)

7215 mm (284.05 in)

B


4250 mm (167.32 in)

5270 mm (207.48 in)

C


4595 mm (180.90 in)

5810 mm (228.74 in)

D


5185 mm (204.13 in)

6645 mm (261.61 in)

E


1065 mm (41.93 in)

1735 mm (68.31 in)

198°

195°

Bucket digging angle


23

695ST CENTER PIVOT

Front and rear tyres ...............................................................................................................440/80 R28 IT530 Standard backhoe bucket ...................................................................................................... 914 mm (35.98 in) Standard dipper


A


6190 mm (243.70 in)

7215 mm (284.05 in)

B


4250 mm (167.32 in)

5270 mm (207.48 in)

C


4595 mm (180.90 in)

5810 mm (228.74 in)

D


5185 mm (204.13 in)

6645 mm (261.61 in)

E


1065 mm (41.93 in)

1735 mm (68.31 in)

198°

195°


Copyright © 24


MAXIMUM LIFTING LOADS LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE 2WS

4WS

Copyright © SECTION 02 - TECHNICAL SPECIFICATIONS BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE 2WS (580T - 580ST)

2WS (590ST)

4WS (695ST)

25

Copyright © 26


SUPPLY SUMMARY TABLE RECOMMENDED FLUIDS AND APPLICATION ENGINE - OIL Akcela No 1 Engine oil

CASE Specifications

INTERNATIONAL Specifications

MODELS

QUANTITY Litres

Gal

2WS - with filter 4WS - with filter

14 12.8

3.70 3.40

MS 1121

API CH-4, ACEA E5, 15W40

MS 1710

ASTM D6210

ALL

24

6.30

MAT 3525

API GL4 ISO VG 32/46 10W-30

2WS 4WS

140 118

36.90 31.10

Akcela Hydraulic Excavator Fluid Bio MS 1230

ISO VG 46 DIN 51524 - part II

2WS 4WS

140 118

36.90 31.10

POWERSHUTTLE TRANSMISSION Akcela Hy-tran Ultra

API GL4, 80W - 140

2WD 4WD

18.5 20.8

4.07 4.57

ALL

20.8

4.57

2WD

0.2

0.10

Differential

6.5

1.70

Wheel reduction gear (each)

0.7

0.20

Differential

10.5

2.80


1.3

0.34

15.5

3.41

17

3.74

Differential

11

2.90


1.3

0.34

2WS 4WS

145 124

38.20 32.70

COOLING SYSTEM Akcela Premium Anti-freeze antifreeze 50% water 50% HYDRAULIC SYSTEM Akcela Nexplore

MS1209

POWERSHIFT TRANSMISSION Akcela Hy-tran Ultra FRONT AXLE (2WS) Akcela Transaxle fluid 80W -140

MS1317 4WD

FRONT AXLE (4WS) Akcela Transaxle fluid 80W -140 REAR AXLE (2WS) Akcela Transaxle fluid 80W -140

Differential 580T-580ST 590ST

REAR AXLE (4WS) Akcela Transaxle fluid 80W -140 FUEL Decanted and filtered diesel fuel VARIOUS JOINTS Akcela Multi-purpose grease

251H EP

NLGI 2

ALL

As required

TELESCOPIC DIPPER Akcela Moly Grease

251 H EP-M

NLGI 2

ALL

As required

ALL

240

AIR CONDITIONING COMPRESSOR PAG SP 20 oil

cm

3

14.6 in 3

Copyright ©

580T 580ST 590ST 695ST

SECTION 21 - TRANSMISSION POWERSHUTTLE TRANSMISSION................................................................................................................ 3 TECHNICAL SPECIFICATIONS.................................................................................................................. 4 CONTROLS ................................................................................................................................................. 9 LUBRICATION........................................................................................................................................... 13 GREASING ................................................................................................................................................ 16 REMOVAL FROM MACHINE .................................................................................................................... 18 DISASSEMBLY AND ASSEMBLY............................................................................................................. 19 TROUBLESHOOTING............................................................................................................................. 144 REPAIR TIMES........................................................................................................................................ 148 SPECIAL TOOLS..................................................................................................................................... 149 POWERSHIFT TRANSMISSION.................................................................................................................. 150 TECHNICAL SPECIFICATIONS.............................................................................................................. 150 CONTROLS ............................................................................................................................................. 161 LUBRICATION......................................................................................................................................... 163 GREASING .............................................................................................................................................. 165 REMOVAL FROM MACHINE .................................................................................................................. 166 DISASSEMBLY AND ASSEMBLY........................................................................................................... 167 TROUBLESHOOTING............................................................................................................................. 331 REPAIR TIMES........................................................................................................................................ 335 SPECIAL TOOLS..................................................................................................................................... 336

Copyright © 2

SECTION 21 - TRANSMISSION

Copyright © SECTION 21 - TRANSMISSION

POWERSHUTTLE TRANSMISSION This transmission is used on powershuttle backhoe loader models 580T - 580ST - 590ST.

3

Copyright © 4


TECHNICAL SPECIFICATIONS 2WD/2WS TRANSMISSION - POWERSHUTTLE (580T) Model ..................................................................................................................... CARRARO TLB1 MPB 2WD Type (4x4) ................................................................................................. 4 forward and 4 reverse travel gears Torque converter ratio .................................................................................................................................. 2.38 Transmission ratios: 1st gear .........................................................................forward travel 5.603:1


2nd gear ........................................................................forward travel 3.481:1


3rd gear.........................................................................forward travel 1.585:1


4th gear .........................................................................forward travel 0.793:1


4WD/2WS TRANSMISSION - POWERSHUTTLE (580ST - 590ST) Model ..................................................................................................................... CARRARO TLB1 MPB 4WD Type (4x4) ................................................................................................. 4 forward and 4 reverse travel gears Torque converter ratio .................................................................................................................................. 2.38 Transmission ratios: 1st gear .........................................................................forward travel 5.603:1








Copyright © SECTION 21 - TRANSMISSION DIMENSIONS 2WD

5

Copyright © 6 4WD



7

PORTS 2WD

Ref. Dimension 1 7/8” - 14 UNF 2 7/8” - 14 UNF 3 1/2” - 14 UNF 4 5

Use Oil inlet from cooler Oil outlet to cooler Transmission temperature switch Oil drain plug

1/8” - 28 BSP ISO 228 Oil cooler return

Notes - Miscellaneous

0.5 + 3.5 bar (7.3 + 50 psi) ON forward / reverse travel position 0.5 + 3.5 bar (7.3 + 50 psi) ON neutral position 11 + 13 bar (159 + 188 psi)

6

7

8 9 10 11 12 13

1/8” - 28 BSP ISO 228 Forward gear pressure check port 0.3 bar (4.3 psi) = maximum pressure in neutral position 11 + 13 bar (159 + 188 psi) 1/8” - 28 BSP ISO 228 Reverse gear pressure check port 0.3 bar (4.3 psi) (4.3 psi) = maximum pressure in neutral position 11 + 13 bar (159 + 188 psi) Forward / reverse gear clutch 1/8” - 28 BSP ISO 228 0.3 bar (4.3 psi) = maximum pressure in neutral pressure check port position 1/8” - 28 BSP ISO 228 Converter pressure check port 0.5 + 0.9 bar (7.3 + 13 psi) 9/16” - 18 UNF Oil inlet / outlet for differential lock 13 bar (188 psi) at 900 rpm 9/16” - 18 UNF Brake oil outlet / inlet 14.5 bar (210 psi) at 2200 rpm 9/16” - 18 UNF Oil inlet from the brake Oil inlet from service pump to 9/16” - 18 UNF Brake pressure switch = 10 ± 1 bar (145 ± 14 psi) brake release

Copyright © 8


4WD

Ref. Dimension 1 7/8” - 14 UNF 2 7/8” - 14 UNF 3 1/2” - 14 UNF 4 5

Use Oil inlet from cooler Oil outlet to cooler Transmission temperature switch Oil drain plug

1/8” - 28 BSP ISO 228 Oil cooler return

Notes - Miscellaneous

0.5 + 3.5 bar (7.3 + 50 psi) ON forward / reverse travel position 0.5 + 3.5 bar (7.3 + 50 psi) ON neutral position 11 + 13 bar (159 + 188 psi)

6

7

8 9 10 11 12 13 14

1/8” - 28 BSP ISO 228 Forward gear pressure check port 0.3 bar (4.3 psi) = maximum pressure in neutral position 11 + 13 bar (159 + 188 psi) 1/8” - 28 BSP ISO 228 Reverse gear pressure check port 0.3 bar (4.3 psi) = maximum pressure in neutral position 11 + 13 bar (159 + 188 psi) Forward / reverse gear pressure 1/8” - 28 BSP ISO 228 0.3 bar (4.3 psi) = maximum pressure in neutral check port position 1/8” - 28 BSP ISO 228 Converter pressure check port 0.5 + 0.9 bar (7.3 + 13 psi) 9/16” - 18 UNF Oil inlet / outlet for differential lock 13 bar (188 psi) at 900 rpm 9/16” - 18 UNF Brake oil outlet / inlet 14.5 bar (210 psi) at 2200 rpm 9/16” - 18 UNF Oil inlet from the brake Oil inlet from service pump to 9/16” - 18 UNF Brake pressure switch = 10 ± 1 bar (145 ± 14 psi) brake release 13 + 14 bar (188 + 203 psi) at 900 rpm 4WD pressure check port 13 + 15.5 bar (188 + 225 psi) at 2200 rpm

Copyright © SECTION 21 - TRANSMISSION CONTROLS

1. GEARSHIFT LEVER: it is possible to select four forward and four rearward travel gears. 2. TRANSMISSION DISCONNECT BUTTON (on gearshift lever): prior to gearshifting, press and hold this switch; select the desired gear with the gearshift lever and release the switch to reengage transmission. 3. REVERSE TRAVEL LEVER: the movement of this lever from the neutral position will engage the forward or reverse travel. 4. the warning horn activates in reverse travel. 5. HORN BUTTON 6. TRANSMISSION DISCONNECT BUTTON (on loader attachment control lever).

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The transmission provides 4 forward and 4 reverse speeds. A torque converter is used to couple the engine with the transmission. The reverse travel lever (3) allows shifting between forward and reverse travel without disengaging the gear ratios. A device for “transmission disconnection” is activated by pushing button (2), placed on the gearshift lever (1) or by pushing button (5), placed on the loader attachment (3) control lever.

WARNING Always apply the parking brake whenever the machine is parked as the machine is free to roll even though the transmission gearshift lever and power reversing lever may be “In Gear” and the engine is turned OFF.

GEARSHIFT LEVER The gearshift lever (1) is used to select any of the 4 gear ratios. The transmission disconnect button (2) is depressed and held as the lever is shifted from one gear to another. The button is then released to reestablish the power of transmission drive.

FORWARD/REVERSE POWERSHUTTLE LEVER (TRAVEL DIRECTION CHANGE) To select the forward travel, engage the required gear ratio with the gearshift lever. With the engine idling, lift the powershuttle lever from the neutral lock position (1) and move it to the forward position (2). Use the accelerator pedal to control the engine rpm and the ground speed. To reverse the direction of travel, reduce engine speed and move the power reversing from neutral lock position (1) and rearwards (3) for reverse travel (audible alarm device sounds). IMPORTANT: the powershuttle lever is equipped with a neutral lock to prevent an accidental engagement of the transmission. With this design, the powershuttle lever moves through a “T” slot to the forward or reverse positions.

Copyright © SECTION 21 - TRANSMISSION IMPORTANT: when operating at low environmental temperatures with cold transmission oil, allow the oil to warm up before attempting to shift the powershuttle lever. The transmission can be shifted normally after the oil warms up. IMPORTANT: the horn will sound if the powershuttle lever is operated with the parking brake engaged. IMPORTANT: The powershuttle lever can be activated with any engine speed. As a safety and precautionary measure, the engine must run at approximately 1200 rpm. This action is easily controlled by means of the foot accelerator to control engine and ground speed.

TRANSMISSION DISCONNECTION The 4x4 transmission provides for easy upward and downward gear ratio changes on the move. However, as a clutch is not used between the engine and transmission, the power flow from the engine to the transmission must be interrupted to shift from one gear ratio to another. This is accomplished by means of a transmission disconnect (dump) button. The finger operated button (2) on the main gearshift lever knob (1) is easy to operate.

WARNING Do not use the disconnect switch control down hill, because excessive speed may cause loss of control, personal injury or the failure of transmission. To make upward gear ratio changes, simply depress and hold button (2) on the gearshift lever (1), while shifting the same from one gear ratio to another. When the desired gear ratio has been selected release the button and allow the unit to gain engine speed and ground speed. If another higher ratio is required repeat the procedure.

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IMPORTANT: to prevent possible damages to the transmission hydraulic clutches, never use the disconnect switch for inching the machine forward, because this will cause the clutches to slip excessively and to overheat. To make downward gear ratio changes or reduce ground speed, simply lower the engine speed, depress and hold the gearshift lever button and downshift the transmission. When the desired gear ratio has been selected release the button and adjust the engine speed to suit ground speed required. Operating the machine in a too high gear or under a too heavy load will cause the torque converter to slip excessively and overheat. If the machine is overloaded, the engine speed will not exceed a range of 1800-2200 rpm at maximum accelerator and the torque converter will “stall” bringing the machine to a complete stop. If “stall” does occur, there is still sufficient engine power to operate the loader attachment; however, to prevent the transmission from overheating, either reduce the load on the machine or select a lower gear ratio. IMPORTANT: operating at a “stall” for more than 20 seconds can cause the transmission to overheat and can possibly damage the transmission. If the transmission overheats, the needle (3) reaches the red field. Shift both the powershuttle lever and the gearshift lever to neutral. Let the engine run idle (1000 rpm) until transmission oil cools down enough to have the needle (3) return to correct position.

Copyright © SECTION 21 - TRANSMISSION LUBRICATION 2WD

4WD

1. Oil filler tube interface 2. Oil drain plug 3. Breather

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LEVEL CHECK The oil level check should be carried out with the engine running at low speed and at normal operating temperature. Move the machine to a level and firm ground. Raise the loader attachment and assemble the safety support strut. Place the backhoe attachment in the road travel position. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Open and raise the engine guard and lock it in opened position by means of the safety lock on the left-hand gas spring. Extract the dipstick (1), clean it with a clean cloth and completely insert it into the tube, then take it out again. If the oil level is below the mini mark, top up. Stop the engine. Unlock the safety lock and close the engine guard.

Copyright © SECTION 21 - TRANSMISSION OIL CHANGE Move the machine to a level and firm ground. Raise the loader attachment and assemble the safety support strut. Place the backhoe attachment in the road travel position. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Stop the engine and remove the starter key. Open and raise the engine guard and lock it in opened position by means of the safety lock on the left-hand gas spring. Remove the dipstick (1). NOTE: change the oil while the transmission is still warm; the oil will flow more easily. Place a container with suitable capacity under the drain plug (2). Unscrew and remove the drain plug. Let the transmission oil drain.

Re-install the drain plug (2). Fill with new oil of specified type through the dipstick hole. NOTE: transmission oil capacity 18.5 litres (4.07 gal) (2WD) and 20.8 litres (4.57 gal) (4WD). Reassemble the dipstick (1). Check the oil level by means of the dipstick and, if necessary, add more oil. Drive the machine for a few minutes in first and second gear, then stop the engine. Check the oil level again by means of the dipstick and, if necessary, add more oil.

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GREASING Tecnolube POLYMER 400 grease Transmission oil 2WD - 4WD

*: no grease, no oil

Copyright © SECTION 21 - TRANSMISSION ONLY 4WD

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REMOVAL FROM MACHINE

1. Transmission

12. Dipstick tube

2. Anti-vibration

13. Dipstick

3. Left transmission support 4. Right transmission support

14. M10 x 30 hex screw [tightening torque 52 ÷ 57 Nm (38 ÷ 42 lbf·ft)]

5. Washer

15. Washer


16. Torque converter

7. Washer

18. Plate


19. Snap ring

9. Washer


10. M12 nut 11. Fitting (apply Loctite 577)

17. Plate

20. Washer


Copyright © SECTION 21 - TRANSMISSION DISASSEMBLY AND ASSEMBLY Some of the following pictures could not exactly show your transmission, but the procedure is correct. TIGHTENING TORQUES AND APPLICATION OF SEALANTS / ADHESIVES A. Loctite 510 B. Loctite 518

C. Loctite 638 D. Loctite 542

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Copyright © SECTION 21 - TRANSMISSION Only 4WD

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PLUGS AND FILTERS

Disassembly Remove the oil drain plug (5) and drain the oil from the transmission.

Loosen and remove the 2 screws (1). Remove the cap (2).

Copyright © SECTION 21 - TRANSMISSION Remove the oil filter (4) and the O-ring (3).

Unscrew and remove the oil filter (6).

Remove fitting (7).

Remove the spool (8).

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Remove the spring (9).

Use a puller to remove the pressure relief valve (10). NOTE: the pressure relief valve is adjusted by the Manufacturer. Never disassemble nor adjust it. If any of its parts are damaged, replace the valve with a new one.

Do not remove the plug unless there are leaks. The plug is sealed with Loctite 542 and is difficult to remove. If the removal is necessary, clean it and apply Loctite 542 prior to assembly.

If necessary, remove the plugs (13) or the breather (11).

Copyright © SECTION 21 - TRANSMISSION Assembly Assemble the plugs (13) and the breather (11).

Assemble valve (10).

Assemble the spring (9).

Assemble the spool (8).

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Assemble fitting (7). Tighten to the prescribed torque of 80 Nm (59 lbf·ft).

Assemble a new oil filter (6). Lubricate the gasket. Tighten clockwise until the gasket makes contact with its seat, then tighten further 2/3 of a turn.

Assemble the oil filter (4) and the O-ring (3).

Assemble the cover (2). Screw in and tighten the screws (1) to a tightening torque of 23 Nm (17 lbf·ft).

Copyright © SECTION 21 - TRANSMISSION Assemble the plug (5). Tighten to the prescribed torque of 30 Nm (22 lbf·ft).

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OIL PUMP

Disassembly Loosen and remove the screws (1). Mark the oil pump position with respect to the bell housing before loosening the screws.

Use two levers (A) to pull out the oil pump (2).

Copyright © SECTION 21 - TRANSMISSION Remove the oil pump (2). The pump seal ring can be damaged during this operation.

If necessary, remove the O-ring (3).

WARNING Do not disassemble the pump or its operation may be compromised.

If necessary, remove the seal ring (4).

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Assembly Assemble the seal ring (4) onto the oil pump (2). Use tool 380200218. Lubricate the seal ring.

Assemble the O-ring (3).

Before pump assembly (if new), check that the oil passage holes (between pump and half box) or the visual marks coincide.

Lubricate the seal ring (4) to keep it centred, in order to facilitate its introduction onto the oil pump.

Copyright © SECTION 21 - TRANSMISSION Lubricate the matching seat with the front half box. Assemble the oil pump (2).

Screw in and tighten the screws (1) to a tightening torque of 23 Nm (17 lbf·ft). Check that the mark on the oil pump and on the bell housing coincide.

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TUBES

Disassembly Drain transmission oil. Loosen and remove the screws (1) and (2). Remove the tube (3). Collect the gaskets (4).

Assembly Assemble the tube (3) with the gaskets (4). Screw in and tighten the screws (1) and (2) to the prescribed torque of 40 Nm (30 lbf·ft).

Copyright © SECTION 21 - TRANSMISSION HYDRAULIC CONTROL VALVE

Disassembly Disconnect all electric connections. Drain the transmission oil. Loosen and remove the screws (13). Remove the hydraulic control valve (53).

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Remove the gasket (49).

Remove the screws (48), and the plate (50).


Lock the hydraulic control valve with a clamp. Remove the plug (1) and the O-ring (2).

Copyright © SECTION 21 - TRANSMISSION Push piston (4) downwards and remove the snap ring (3).

Remove the piston (4) and the spring (5).

Verify the wear condition of the piston (4) and of the spring (5).

Do not disassemble the piston (8) from the control valve body. If the piston is to be disassembled (8), the control valve body must be replaced (47). If the piston (8) is to be replaced, also order the control valve body (47).

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Remove the plug (6) and the O-ring (7).


Remove the washer (10).

Loosen and remove the screws (33).

Copyright © SECTION 21 - TRANSMISSION Remove the valve cover (34).


Remove the plate (36).

Remove the outer piston (38), the springs (39), (40) and (41), the pin (42) and the inner piston (43).

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Verify the wear condition of the springs (39), (40) and (41) and of the pin (42).


Remove the ball (26).


Copyright © SECTION 21 - TRANSMISSION Remove the plug (32) and the O-ring (31).

Remove the solenoid valve coil (30) and the O-ring (29).

Remove the solenoid valve coil (28) and the O-ring (27).

Unscrew the solenoid tube (24).

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Remove the solenoid tube (24) with the piston (21).

Disassemble the piston (21) and the solenoid tube (24).

Remove the spring (23) and the washer (22). Verify the wear condition of the piston (21) and of the solenoid tube (24).

Unscrew and remove the nut (20).

Copyright © SECTION 21 - TRANSMISSION Remove the O-ring (19). Remove the solenoid valve coil (18) and the O-ring (17).

Unscrew the solenoid tube (18).

Remove the O-rings (17).

Verify the wear condition of the solenoid tube (18), of the O-ring (19) and of the nut (20).

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Assembly Assemble the O-rings (17).

Assemble the solenoid tube (18). Tighten to the prescribed torque of 25 ÷ 30 Nm (18 ÷ 22 lbf·ft).

Assemble the O-ring (17). Assemble the solenoid coil (18). Assemble the O-ring (19).

Screw in and tighten the nut (20) to the tightening torque of 5 ÷ 7 Nm (3.6 ÷ 5 lbf·ft).

Copyright © SECTION 21 - TRANSMISSION Assemble the solenoid tube (24), the spring (23), the piston (21) and the washer (22).

Assemble the solenoid tube (24) and the piston (21).

Screw in and tighten the solenoid tube (24) to a tightening torque of 21.5 ÷ 24.5 Nm (15.9 ÷ 18 lbf·ft).

Assemble the O-ring (27). Assemble the solenoid coil (28).

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Assemble the O-ring (29). Assemble the solenoid coil (30).

Assemble the O-ring (31) on the plug (32). Assemble the plug (32). Tighten to the prescribed torque of 7 ÷ 10 Nm (5 ÷ 7.4 lbf·ft).

Insert the spring (25).

Insert the ball (26).

Copyright © SECTION 21 - TRANSMISSION Position the gasket (37).

Pre-assemble the springs (39), (40) and (41) and the pin (42) with the pistons (38) and (43).

Assemble the outer piston (38), the springs (39), (40) and (41), the pin (42) and the inner piston (43).

Position the plate (36).

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Position and lubricate the gasket (35).

Assemble the valve cover (34).

Screw in and tighten the screws (33) to a tightening torque of 9.8 ÷ 11.8 Nm (7 ÷ 8.7 lbf·ft).

Turn the hydraulic control valve (47). Assemble the washer (10).

Copyright © SECTION 21 - TRANSMISSION Assemble the spring (9).

Assemble the O-ring (7) on the plug (6). Screw in and tighten the plug (6) to the tightening torque of 80 Nm (59 lbf·ft).

Assemble the piston (4) and the spring (5).

Push piston (4) downwards and assemble the snap ring (3).

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Assemble the O-ring (2) on the plug (1). Screw in and tighten the plug (1) to the tightening torque of 80 Nm (59 lbf·ft).

Position and lubricate the gasket (51).

Assemble the plate (50). Screw in and tighten the screws (40) to a tightening torque of 50 Nm (37 lbf·ft).

Position and lubricate the gasket (49). Lubricate the gasket (49).

Copyright © SECTION 21 - TRANSMISSION Assemble the hydraulic control valve (53). Screw in and tighten the screws (13) to a tightening torque of 15 ÷ 24.2 Nm (11 ÷ 17.9 lbf·ft).

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4WD SOLENOID VALVE

Disassembly Prior to disassembling the 4WD solenoid valve, disconnect all electric connections. Drain the transmission oil. Loosen and remove the screws (1). Remove the solenoid body (2).

Copyright © SECTION 21 - TRANSMISSION Remove the nut (8). Remove the solenoid valve coil (7).

Remove the shaft (6). Remove the O-rings (5).


If necessary, remove the valve (3). Do not disassemble the valve (3). There are no serviceable parts. If there is a problem, use a new valve.

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Assembly Assemble valve (3).

Assemble the O-rings (5) on the shaft (6).

Assemble the 4WD solenoid coil (7). Screw in and tighten the nut (8) to the tightening torque of 5 ÷ 8 Nm (3.6 ÷ 5.9 lbf·ft).

Position the gasket (4).

Copyright © SECTION 21 - TRANSMISSION Remove the solenoid body (2). Screw in and tighten the screws (1) to a tightening torque of 23 Nm (17 lbf·ft).

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PARKING HANDBRAKE

Disassembly Drain the transmission oil.

Unscrew the screw (1). Use a screwdriver and 2 screws to lock the flange. Remove the screw (1) and the washer (2). Remove the flange (4) and the O-ring (3).

Copyright © SECTION 21 - TRANSMISSION Loosen and remove the screws (5), (6) and (7). Remove the brake (8) assembly. Remove the O-ring (9) from the brake (8).

Remove the seal ring (15). Remove the plug (16).

WARNING The seal ring can be damaged.

Remove the rings (10), the 5 brake discs (11) and the 5 counterdiscs (12).

Remove the hub (13).

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Assembly Assemble the hub (13).

Use a gauge to check that each counterdisc (12) and each brake disc (11) is flat. If necessary, replace them. If the brake discs (11) are nearly smooth, replace them. If the friction material is damaged or appears burned, replace it. Check the grooves for wear. Check counterdiscs (12) for pitting, scoring, or other damage. If necessary, replace them. If you will be using new brake discs, soak them in oil for at least an hour before assembly. If you are using the old friction discs, make sure that the contact surfaces are coated with oil before assembly, check the wear condition. If this is 50% compared to the nominal value, we suggest its replacement.

Brake disc kit Brake disc number

5

Counterdisc number

5

Nominal brake disc thickness

3.6 ± 0.05 mm (0.14 ± 0.002 in)

Brake disc kit nominal thickness [with 163 kg (359.34 lbs) of load] Brake disc maximum wear (each side)

37.40 ÷ 37.60 mm (1.47 ± 1.48 in) 0.65 mm (0.02 in)

Copyright © SECTION 21 - TRANSMISSION Assemble the counterdisc (12), the brake disc (11) and the ring (10). Repeat this operation until the brake disc kit is complete.

Assemble the plug (16). Assemble the seal ring (15) onto the brake (8), use tool 380200226.

Insert the O-ring (9) on the brake (8). Assemble the brake assy (8) on transmission. Screw in and tighten the screws (5), (6) and (7) to a tightening torque of 50 Nm (37 lbf·ft).

Assemble the flange (4) and the O-ring (3). Lubricate the O-ring (3). Assemble the washer (2) and the screw (1). Use a screwdriver and 2 screws to lock the flange (A). Tighten the screw (1) to a tightening torque of 139 Nm (102.5 lbf·ft).

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Copyright © 58 2WD - TRANSMISSION BOX

Disassembly Remove the snap ring (1).


Copyright © SECTION 21 - TRANSMISSION Loosen and remove the screws (2). Remove the gearshift control assy (3) and the O-ring (4).

Loosen and remove the screws (5). Remove flange (6).

Loosen and remove the screws (7). By means of a lever loosen the cover. Remove the rear cover (8).

Remove the O-ring (9).

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Remove the pins (10) by means of a punch.

Remove the retainers (12).

Loosen and remove the 2 screws (13).


Copyright © SECTION 21 - TRANSMISSION Remove the 2 balls (15).

Loosen and remove the screws (16) and the washers (17).

Remove the springs (18).

Remove the balls (19).

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Pull the secondary shaft to the rear so that there is backlash between the snap ring and the rear housing. Remove the snap ring (20).

Remove transmission shaft PTO (21) by pushing lightly on the opposite side.

If necessary, replace the seal ring (22) by cutting it.

Remove the snap ring (23).

Copyright © SECTION 21 - TRANSMISSION Take out the bearing (24) with tool 380200190.


Use lever (A) to remove the front half box (26).

The outer rings of the bearings (27) and (28) can either stay on the shafts or on the front box seat. Remove the 2 bearings (27) and (28).

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If necessary, remove the O-rings (29).

Assembly Push the secondary shaft toward the back of the rear box, so that there is backlash between the snap ring seat and the rear box. Assemble the snap ring (20).

Assemble the O-rings (29). Do not apply any grease/oil on O-rings.

Apply a thin film of sealant on the edge of the rear half box.

Copyright © SECTION 21 - TRANSMISSION Lubricate and assemble the bearings (27) and (28).

Assemble the front half box (26). Make sure that the bearings of the shafts go straight into the bores in the front box.

Screw in and tighten the screws (25) to a tightening torque of 50 Nm (37 lbf·ft).

Assemble the snap ring (1).

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Insert the ball (19). NOTE: previously, the parts of the 1st and 2nd gear lower control have been installed. It is necessary to install both the upper control parts for 3rd and 4th speed and the lower ones for 1st and 2nd speed, according to the instructions given by the procedure. Make sure that you start with both shift rods in the neutral position.


Assemble the washer (17) and the screw (16). Tighten the screw (16) to a tightening torque of 80 Nm (59 lbf·ft).

Insert the ball (19) and the spring (18). Assemble the screw (16) and the washer (17). Tighten the screw (16) to a tightening torque of 80 Nm (59 lbf·ft).

Copyright © SECTION 21 - TRANSMISSION Assemble the bearing (24) on the transmission shaft PTO (21).


To assemble the seal ring (22) perform following operations by means of the listed tools in sequence: 380200257; 380200225; 380200214.

Insert transmission shaft PTO (21) to stroke end.

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Grease the balls. Insert the 2 balls (15).

Assemble the plate (14).

Apply sealant on the threads of the 2 screws. Screw in the 2 screws (13) to fasten the plate correctly and tighten them to the prescribed torque of 50 Nm (37 lbf·ft).

Assemble the retainers (12) on the gearbox pins.

Copyright © SECTION 21 - TRANSMISSION Assemble the pins (10) to fasten retainers on the gearbox pins and the dowel pins (11).

Apply a thin film of sealant on the edge of the rear cover (8). Assemble the O-ring (9). Do not grease the O-ring.

Place the rear cover (8). Make sure that the pin (11) is correctly installed both in the rear box and in the hole of the rear cover. Tighten the screws (7) to fasten the cover on the rear half box at the tightening torque of 50 Nm (37 lbf·ft). If necessary, tap the rear cover with a soft faced hammer to close the gap between the rear half housing and the rear cover to tighten the cap screws.

Apply a thin film of sealant on the edge of the flange (6). Place the flange (6). Screw in and tighten the screws (5) to a tightening torque of 50 Nm (37 lbf·ft).

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Assemble a new O-ring (4) on the gearshift control assy (3). Use clean oil to lubricate the ring and assembly it on the rear box. Screw in the 3 screws (2) fastening the gearshift control assy to the rear cover and tighten to the prescribed torque of 23 Nm (17 lbf·ft).

Copyright © SECTION 21 - TRANSMISSION 4WD - TRANSMISSION BOX


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Loosen and remove flange retaining screw (2). Use a screwdriver and 2 screws to prevent the flange rotation.


Remove the flange (5) and the O-ring (4).


Copyright © SECTION 21 - TRANSMISSION Remove cover (7).

Remove the O-ring (8) from the cover (7).

Remove the seal ring (9) from rear cover (7).

Loosen and remove the 3 screws (10). Remove the gearshift control assy (11) and the O-ring (12).

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Loosen and remove the 7 screws (13) and the flange (14).

Loosen and remove the screws (15) fastening the cover (16). Use a prybar to loosen the rear cover from the housing. Remove the rear cover (16).


Remove the pins (18) by means of a punch.

Copyright © SECTION 21 - TRANSMISSION Remove the retainers (20).



Remove the 2 balls (23).

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Loosen and remove the screws (24) and the washers (25).

Remove the springs (26).

Remove the balls (27).

Pull the secondary shaft to the rear so that there is backlash between the snap ring and the rear housing. Remove the snap ring (28).

Copyright © SECTION 21 - TRANSMISSION Remove transmission shaft PTO (29) by pushing lightly on the opposite side.



Take out the bearing (32) with tool 380200190.

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Use a lever to remove the front half box (35). Raise the front half box.

The outer rings of the bearings on the primary shaft (36) and on the secondary shaft (37) can either stay on the shafts or on the front box seat. Remove the 2 bearings (36) and (37).

Copyright © SECTION 21 - TRANSMISSION Remove the bearing (38).

If necessary, replace the O-rings (39).

Assembly Push the secondary shaft toward the back of the rear box, so that there is backlash between the snap ring seat and the rear box. Assemble the snap ring (28).

Assemble the O-rings (39).

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Apply a thin film of sealant on the edge of the rear half box.

Lubricate the primary shaft bearing (36) and the secondary shaft bearing (37). Assemble the 2 bearings (36) and (37).

Assemble the front half box (35) on the rear one. Make sure that the bearings of the shafts go straight into the bores in the front box. Push the front half box onto the rear one.


Copyright © SECTION 21 - TRANSMISSION Screw in and tighten the screws (33) to a tightening torque of 50 Nm (37 lbf·ft).

Lubricate the bearing of the 4WD shaft. Assemble the bearing (38) on 4WD shaft by means of tool 380200230.

By means of tool 380200213 assemble the seal ring (9) on the cover (7). Push just until the seal ring stops moving. Do not use excessive force. Fill the cavity under the lip with grease.


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Assemble the cover (7).

Screw in the 3 screws (6) fastening the cover to the front box and tighten them to a tightening torque of 23 Nm (17 lbf·ft).

Assemble and lubricate the O-ring (4) in the 4WD flange.

Assemble the 4WD flange (5).

Copyright © SECTION 21 - TRANSMISSION Assemble the washer (3).

Screw in the screw (2). Use a screwdriver to prevent the flange rotation. Tighten the screw (2) to a tightening torque of 139 Nm (102.5 lbf·ft).


Insert the ball (27). NOTE: later on the parts of the 1st and 2nd gearshift lower control will be installed. It is necessary to install both the upper control parts for 3rd and 4th speed and the lower ones for 1st and 2nd speed, according to the instructions given by the procedure. Make sure that you start with both shift rods in the neutral position.

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Assemble the washer (25) and the screw (24). Tighten the screw (24) to a tightening torque of 80 Nm (59 lbf·ft).

Insert the ball (27) and the spring (26). Assemble the screw (24) and the washer (25). Tighten the screw (24) to a tightening torque of 80 Nm (59 lbf·ft).

Assemble the bearing (32) on the transmission shaft PTO (29).

Copyright © SECTION 21 - TRANSMISSION Assemble the snap ring (31).

To assemble the teflon seal ring (30) perform following operations by means of the listed tools in sequence: 380200257 (without shim); 380200225; 380200214.


Grease the balls. Insert the 2 balls (23).

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Copyright © 86


Assemble the plate (22).

Apply sealant on the threads of the 2 screws. Screw in the 2 screws (21) to fasten the plate correctly and tighten them to the prescribed torque of 50 Nm (37 lbf·ft).

Assemble the retainers (20) on the gearbox pins.

Assemble the pins (18) to fasten the retainers on the gearshift pins.

Copyright © SECTION 21 - TRANSMISSION Apply a thin film of sealant on the edge of the rear cover (16). Assemble the O-ring (17). Do not grease the O-ring.

Place the rear cover (16). Make sure that the pin (19) is correctly installed both in the rear box and in the hole of the rear cover. Tighten the screws (15), to fasten the cover on the rear half box at the tightening torque of 80 Nm (59 lbf·ft). If necessary, tap the rear cover with a soft faced hammer to close the gap between the rear half housing and the rear cover to tighten the cap screws.

Apply a thin film of sealant on the edge of the flange (14). Place the flange (14). Screw in and tighten the screws (13) to a tightening torque of 50 Nm (37 lbf·ft).

Assemble a new O-ring (12) on the gearshift control assy (11). Use clean oil to lubricate the ring and assembly it on the rear box. Screw in the 3 screws (10) fastening the gearshift control assy to the rear cover and tighten to the prescribed torque of 23 Nm (17 lbf·ft).

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SHAFTS A, D

Disassembly Grab the shaft with the (A) pliers and pull out the shaft assy (D).

Copyright © SECTION 21 - TRANSMISSION Shaft (A) If necessary, remove the seal ring (1).


Assemble a bearing separator under the gear (do not assemble the bearing separator between the gear and the bearing). Use a puller on the bearing separator and insert a shaft protector between the puller and the end of the input shaft. By means of puller which operates between separator and shaft protection, pull only until the bearing is free, otherwise the parts can be damaged.

Remove the bearing (3).

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Copyright © 90 Remove the spacer (4).

Remove the gear (6).

Remove the roller retainer (7).

Remove the thrust washer (8).


Copyright © SECTION 21 - TRANSMISSION Remove the pin (9).


Lift and remove the snap ring (11).

Remove the discs (18) and the counterdiscs (17).

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Place a mark below the groove on the clutch bell.

Mark the snap ring (11), the discs (18) and the counterdiscs (17). These marks will be used as a reference during assembly.

Lower the cover (13) by means of tool 380200215.


Copyright © SECTION 21 - TRANSMISSION Loosen the knobs of the threaded bars to clear the spring tension. Remove the upper part of tool 380200215.

Remove the cover (13) and the spring (15).

Remove the sleeve (5).

Remove the clutch piston (19) by blowing in compressed air through the delivery hole.

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If necessary, remove the seal ring (20) with the inner O-ring from the outside seat of the piston and the seal ring (21) with the relevant O-ring from the inner seat of the piston. To remove the rings it is necessary to cut them.

Turn the shaft. If necessary, remove the seal rings (22).


Use a puller to remove the bearing (24).

Copyright © SECTION 21 - TRANSMISSION Remove the bearing (24) and the thrust washer (25).

Remove the gear (26) and the roller retainer (12).

For the disassembly of other parts, repeat the operations described previously.

Check the seal ring grooves (large and small) for wear or damage. Check if the output shaft is worn or damaged. Check oil passages in the output shaft to be sure that they are open and free of foreign material. Check the ball bearings and the needle bearings for flat areas, pitting or other damage.

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If you are to re-use the clutch discs, observe the assembly order.

Use a gauge to check that each counterdisc (17) and each clutch disc (18) is flat. If they are not flat, replace them with new ones. If the clutch discs (18) are nearly smooth, or if their friction faces are damaged or burnt, they must be replaced. Check the grooves for wear. Check counterdiscs (17) for pitting, scoring, or other damage. If you will be using new clutch discs, soak them in oil for at least an hour before assembly. If you are using the old clutch discs, make sure that the contact surfaces are coated with transmission oil before assembly, check their wear condition (see chart below). If the wear exceeds the 50% of the rated value, replace them.

Verify the bore and the housing of the input shaft for damage that will cause leakage during the assembly of the clutch. Check if the slots in the housing of the input shaft are damaged by the tangs of the counterdiscs.


97

Forward - reverse gear clutch Disc number (each side)

6

Counterdisc number (each side)

7

Counterdisc rated thickness

2.5 ± 0.05 mm (0.10 ± 0.002 in)

Rated thickness of disc

1.75 ± 0.05 mm (0.07 ± 0.002 in)

Disc maximum wear (each side)

0.2 mm (0.009 in)

Disc number (each side)

6


6

Rated thickness of disc Disc kit nominal thickness [with 163 kg (359.34 lbs) of load] Disc maximum wear (each side)

Shaft (D) Remove the bearing (16) from the shaft (D) by means of a puller.

Remove the bearing (37) from the shaft (D) by means of a puller.

2.4 ± 0.05 mm (0.09 ± 0.002 in) 29.00 ÷ 29.20 mm (1.14 ± 1.15 in) 0.35 mm (0.01 in)

Copyright © 98


Assembly Shaft (A) Assemble the seal ring (20) with the relevant O-ring and the seal ring (21) with the relevant inner O-ring, respectively in the outer and inner seat of the piston.

Apply a thin film of oil on the seal rings.

Insert the piston (19) with tool (T) 380001926.

Copyright © SECTION 21 - TRANSMISSION Assemble the sleeve (5).

Assemble the spring (15) and the cover (13).

Lower the cover (13) and insert the snap ring (14) by means of tool 380200215.

Remove the 380200215 tool and fit the pin (9).

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Copyright © 100


Insert the thrust washer (8).

Insert the roller retainer (7).

To assemble the clutch discs start with the gear (6) on the bench. Assemble the thrust washer (11) so that the reference mark on top of the plate, made during disassembly, is facing towards the gear.

Assemble the discs (18) and the counterdiscs (17) on the gear (6). The assembled clutch disc kit must contain 6 counterdiscs and 6 friction discs.

Copyright © SECTION 21 - TRANSMISSION Use 2 screwdrivers to position the disc kit.


Assemble the spacer (4).

Heat the bearing (3) to 80 ÷ 100 °C (176 ÷ 212 °F). Assemble the bearing (3) with tool 380200190.

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NOTE: for clarity of the seal ring installation procedure, the following photos do not show the disc kit, gear, spacer, bearing, and snap ring installed on the input shaft. Insert the seal ring (1).

Assemble the 380200224 tool onto the input shaft with the chamfered end facing inwards.

Copyright © SECTION 21 - TRANSMISSION Let tool 380200224 slide on the input shaft and above the spacer. The tool will stop in the correct position to install the seal ring in the groove.

Heat the seal ring to 60 ÷ 80 °C (140 ÷ 176 °F) for 5 minutes. Assemble the seal ring on tool 380200224.

Assemble tool 380200225 over tool 380200224 and slide the seal ring until it reaches the groove in the shaft. Remove tools 380200224 and 380200225, the expander/protector and the spacer from the shaft.

Assemble the end of seal compressor 380200214 with the deep chamfer onto the shaft and over the seal ring. Use a back and forth twisting motion to allow the seal compressor to slip over the top of the seal ring and seat this latter into the groove. Be careful not to damage the seal ring. After the seal ring is seated in the groove, remove the seal compressor from the shaft.

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Turn the seal compressor around and slide the end with the narrow chamfer over the shaft and over the seal ring. Leave the seal compressor in place for 15 minutes until the seal ring has cooled and is properly seated in the groove. After the seal ring has cooled, remove the seal compressor from the shaft.

Turn the shaft upside down to carry out the operations described previously. Lubricate the thrust washer (25). Assemble the thrust washer so that the notch in the inner edge fits over the pin. Make sure that the side with the oil grooves is down.

Heat the bearing (24) to 80 ÷ 100 °C (176 ÷ 212 °F). By means of tool 380200197 place the bearing (24) onto the input shaft until it makes contact with the thrust washer.


Copyright © SECTION 21 - TRANSMISSION Assemble the snap rings and place the spacer in the protection (tool 380001933).

Place tool 380001933 and the spacer on the shaft. The tool will stop in the correct position to install the seal ring in the groove.


Assemble tool 380001928 over tool 380001933 and slide the seal ring until it reaches the groove in the shaft. Remove tools 380001928 and 380001933.

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Copyright © 106




Copyright © SECTION 21 - TRANSMISSION In order to insert the other 3 rings, repeat the operations described previously, by means of following spacer rings: 380001933/3 for the 2nd ring; 380001933/2 for the 3rd ring; 380001933/1 for the 4th ring.

1. Lubrication oil passage 2. Forward gear clutch passage 3. Reverse gear clutch passage 4. Forward gear engagement 5. Forward gear clutch disc kit 6. Reverse gear clutch disc kit 7. Reverse gear engagement 8. Input shaft Apply compressed air of approximately 6 bar (87 psi) to the forward clutch passage. Listen for the forward gear piston to move and to lock the relevant clutch disc kit. Try to shift the forward travel gear. It must not turn on the input shaft. Try to shift the reverse travel gear. It must turn freely on the input shaft. If the clutches do not work correctly, disassemble them to find the problem.

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Copyright © 108


Carry out the check procedure of the clutch disc kit play on both sides of the clutch. Position the shaft on a suitable support (S) and apply load F on the counterdisc (11) surface by means of a proper buffer (T), as shown. This operation clears any possible play.

To check the backlash, supply the piston chamber with compressed air at 6 bar (87 psi) and verify the actual stroke “X” with a dial indicator. Determine clearance “X”.

The piston stroke (19) and (38) must be such to ensure a play corresponding to (according to the clutch disc kit) X = 2.15 ÷ 4.10 mm (0.08 ÷ 0.16 in) X = 1.60 ÷ 2.45 mm (0.06 ÷ 0.10 in) If the distance is not within specification, the clutch is probably wrongly installed. Turn the clutch shaft upside down and repeat the operation for the other clutch disc kit.

Copyright © SECTION 21 - TRANSMISSION Shaft (D) Assemble the bearing (16) on shaft (D) by means of tool 380200230.

Assemble the bearing (37) on shaft (D) by means of tool 380200230.

Lubricate with oil the shaft seat (A).

Insert shaft (D) and shaft (A). The operation is correct only if the 2 shafts are fitted at the same time.

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Copyright © 110 SHAFTS B, C

Disassembly Remove the shafts (B) and (C).


Copyright © SECTION 21 - TRANSMISSION Remove the gearshift control yokes. To remove the shaft (C) use tool 380200246.

Shaft (C) By means of a puller remove the bearing (1).

Remove the thrust washer (2) and 3rd speed gear (3).

Remove the 3rd/4th speed synchronizer assy (4).

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Remove the ring (5) from each side of the synchronizer assy. The components of the synchronizer assy are serviced as a complete unit. The synchronizer assy may be disassembled for inspection and cleaning. If some parts are damaged, replace the synchronizer assy.

Use a suitable gauge to measure the backlash between the bottom of the teeth on the synchronizer ring and the edge of the sleeve on the outside of the synchronizer assy. The backlash (S) should be approximately 1.0 mm (0.04 in) with used parts in good condition. If the backlash (S) is 0.5 mm (0.02 in) or less, use a new synchronizer assy. Before disassembly, repeat the measurement on the opposite side of the synchronizer.

Remove the ring (6) from each side of the synchronizer.

Remove the sleeve (7) from the synchronizer hub. When the sleeve is removed from the hub, the spring plates, the hub pins and the hub springs will be released from the hub. Be careful not to lose any of these parts.

Copyright © SECTION 21 - TRANSMISSION Remove the blocks (8), the balls (9), the springs (10) and the synchronizer hub (11). The synchronizer hub contains 3 blocks (8), 3 balls (9) and 3 springs (10).

Remove the 4th speed gear (12).

Turn the shaft. Remove outer ring of bearing (15).

Use a puller to remove inner ring of bearing (15). NOTE: do not try to remove the bearing by pulling the gear since it is locked by snap ring (16).

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Remove the shims (20) and the thrust washer (17).

Remove the pin (19).

Remove the 2nd speed gear (18).

Copyright © SECTION 21 - TRANSMISSION Remove the spacer (21).

Remove the 1st/2nd speed synchronizer assy (23). Remove the synchronizer ring (22).

Remove the steel ring (24) and the sintered ring (25) together. Install the synchronizer with the synchronizer assy. Use a suitable gauge to measure the backlash between the bottom of the teeth on the synchronizer ring and the edge of the sleeve on the outside of the synchronizer assy.

The backlash (S1) should be approximately 1.0 mm (0.04 in) with used parts in good condition. If the backlash (S1) is 0.5 mm (0.02 in) or less, use a new synchronizer assy. Repeat the measurement on the opposite side.

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Remove the ring (26).

Overturn the synchronizer and remove the ring (27) from the other side.

Remove the steel ring (28) and the sintered ring (29) together.

Remove the ring (30).

Copyright © SECTION 21 - TRANSMISSION Support the sleeve on blocks. Push it down and, at the same time, extract the detent devices of sleeve and hub. Remove the sleeve (31).

Remove the balls (32), the blocks (33), the springs (34) and the hub (35).

Remove the spacer (36).

Remove the 1st speed gear (37).

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Copyright © 118 Only with 4WD models Remove the snap ring (38).

Only with 4WD models Remove the 4WD gear (14).

Only with 4WD models Remove the snap ring (13).


Copyright © SECTION 21 - TRANSMISSION Shaft (B) Use a puller to remove the inner ring of bearing (39).

Turn the shaft (41). Remove the bearing (40).

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Assembly Shaft (C) Only with 4WD models Put the secondary shaft on the bench so that the first-second gear end is up. You can use a vice with soft jaws to hold the shaft in position. Install the snap ring (13).

Only with 4WD models Assemble the 4WD gear (14).

Only with 4WD models Assemble the snap ring (38).

Copyright © SECTION 21 - TRANSMISSION Assemble the 1st speed gear (37).


Assemble the 1st/2nd speed synchronizer (23). Before final assembly, check the correct location of the hub (35), sleeve (31), springs (34), blocks (33) and balls (32). The springs are installed on the hub. The blocks are not yet pushed down into the sleeve and are holding the hub outside the sleeve. The balls are loose in the recesses of the blocks.

Use a punch or a screwdriver to push the balls (32) into the blocks and push these latter downwards, so that the balls are on the flat faces of the teeth, but not into the detent grooves. When all the balls are in position, push the hub and the blocks downwards until the balls move into the detent groove.

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Assemble the ring (30).

Lubricate the sintered ring (29) and the steel ring (28). Assemble the sintered ring (29) and the steel ring (28).

Assemble the ring (27). The flat sides of the teeth must be directed upwards.

Overturn the synchronizer and assemble the ring (26) from the other side.

Copyright © SECTION 21 - TRANSMISSION Lubricate the sintered ring (25) and the steel ring (24) with oil. Assemble the sintered ring (25) and the steel ring (24). Install the top synchronizer ring on the synchronizer assy. Make sure that the teeth on the top synchronizer ring are aligned with the teeth inside the sleeve. Push the sleeve upwards until it engages with the teeth on top of synchronizer ring. To do this, you must use enough force to overcome the strength of the detent springs and balls. When the synchronizer ring and the sleeve are engaged, the detent must hold the sleeve in this position. Push the sleeve back to neutral position, turn over the synchronizer assy and repeat the procedure with the lower synchronizer ring. If the sleeve does not engage with the teeth or does not hold the position to which it was shifted, the synchronizer assy is damaged or was not correctly assembled. Disassemble the synchronizer assy to find the problem. Install the ring (22) so that the flat sides of the teeth are directed upwards. Assemble the 1st/2nd speed synchronizer (23).

Install the spacer (21) on the 2nd speed gear (18).

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Assemble the 2nd speed gear (18).

Assemble the pin (19).

Assemble the thrust washer (17) and the shims (20).

Assemble the snap ring (16). Measure the backlash “X” between gear (18) and thrust washer (17): the value must be between 0.2 ÷ 0.42 mm (0.01 ÷ 0.02 in).

Copyright © SECTION 21 - TRANSMISSION Use a thickness gauge.

If backlash “X” is more than the prescribed value, remove the snap ring and the thrust washer from their seats and, using the shims shown in the chart, reach the prescribed value. Correctly assemble the shims (20) between the thrust washer (17) and the snap ring (16). SHIM RANGE Shims mm (in)

0.05 0.1 0.3 (0.002) (0.004) (0.012)

0.5 (0.02)

Heat the inner ring of the bearing (15) to 80 ÷ 100 °C (176 ÷ 212 °F). Assemble the inner ring of the bearing (15) by means of tool 380200203.

Assemble the outer ring of bearing (15).

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Turn the shaft. Assemble the 4th speed gear (12).

Assemble the 3rd/4th speed synchronizer (4). Before final assembly, check the correct location of the hub (11), sleeve (7), springs (10), blocks (8) and balls (9). The springs are installed on the hub. The blocks are now on the spring and not yet on the sleeve and are holding the hub outside the sleeve. The balls are loose in the recesses of the blocks.

Install the 3 sets of blocks (8), balls (9) and springs (10) onto the hub (11). Use a punch or a screwdriver to push the spring plates as the synchronizer hub is installed into the sleeve (7). Be sure that the spring plates are aligned with the grooves of the sleeve.

Assemble the ring (6) on each side of the synchronizer assy.

Copyright © SECTION 21 - TRANSMISSION Use oil to lubricate the ring (5) and install it on each side of the synchronizer assy. Install the top synchronizer ring on the synchronizer assy. Make sure that the teeth on the top synchronizer ring are aligned with the teeth inside the sleeve. Push the sleeve upwards until it engages with the teeth on top of synchronizer ring. To do this, you must use enough force to overcome the strength of the detent springs and balls. When the synchronizer ring and the sleeve are engaged, the detent must hold the sleeve in this position. Push the sleeve back to neutral position, turn over the synchronizer assy and repeat the procedure with the lower synchronizer ring. If the sleeve does not engage with the teeth or does not hold the position to which it was shifted, the synchronizer assy is damaged or was not correctly assembled. Disassemble the synchronizer assy to find the problem. Assemble the 3rd/4th speed synchronizer assy (4) on the shaft.

Lubricate the thrust washer (2). Assemble the 3rd speed gear (3) and the thrust washer (2) on the shaft.

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Heat the inner ring of the bearing (39) to 80 ÷ 100 °C (176 ÷ 212 °F). Assemble the inner ring of the bearing (39) by means of tool 380200203.

Turn the shaft (41). Heat the bearing to 80 ÷ 100 °C (176 ÷ 212 °F). Assemble the bearing (40) with tool 380200190.

Re-position the shaft assemblies (B) and (C) into the half box. Use tool 380200246.

WARNING The shaft assemblies must be inserted with pins and yokes. Insert the pre-fitted yokes for 3rd and 4th speed and for 1st and 2nd speed as shown.

Copyright © SECTION 21 - TRANSMISSION Position the assy with care, paying attention that the ends of the yoke pins are correctly seated.

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Copyright © 130 4WD - E SHAFT

Disassembly Remove the shaft (E).


Copyright © SECTION 21 - TRANSMISSION Remove the 4WD clutch gear (10).


Use tool 380200258 to compress the spring retainer downwards in order to reach the snap ring. Remove the snap ring (1). Release the tension and remove the tool. Remove the washer (2).


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Copyright © 132 Remove the springs (4).


Remove the 2 O-rings (6) and (9).

Remove the seal rings (8).


Copyright © SECTION 21 - TRANSMISSION Remove the 4WD clutch tube (7) from the front box. If necessary, or if the tube is leaking or damaged, replace the front box.

Assembly Assemble and lubricate the O-rings (6) and (9).

Assemble the sleeve (5).

Assemble the springs (4).

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Position the washer (2) and the snap ring (1).

Use tool 380200258 to press the spring retainer down until you have access to the snap ring. Assemble the snap ring (1). Release the tension and remove the tool. Make sure that the snap ring (1) is seated correctly in the recess of the spring retainer.

Place tool 380200207 on the shaft. The tool will stop in the correct position to install the seal ring in the groove. Heat the seal ring (8) to 60 ÷ 80 °C (140 ÷ 176 °F). Assemble the seal ring on the tool.

Copyright © SECTION 21 - TRANSMISSION Assemble tool 380200225 on tool 380200207 and slide the seal ring until it reaches the groove of the shaft. Remove tools 380200225 and 380200207 and the spacer from the shaft.



Insert tool 380200208. Repeat the previously described operations to insert the second ring. Lubricate the seal rings.

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Apply compressed air at about 6 bar (87 psi) to 4WD clutch oil passage (see arrow) by plugging the opposite hole with a finger. The sleeve (5) should move when compressing the springs (4). The 4WD gear (10) should turn freely on 4WD shaft. If the operation is not correct, dismantle to find the problem.

Copyright © SECTION 21 - TRANSMISSION Assemble the bearing (11).

Assemble the gear (10).

Assemble the shafts (B) and (C). Assemble shaft (E).

Reassemble the 4WD clutch tube (7), if previously removed from the front box. Assemble the front half box on the rear half box.

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SPEED CONTROLS

Disassembly Loosen and remove the screws (1). For the disassembly of the two half boxes it is necessary to remove the gearshift control assy. Remove the gearshift control assy (2) and the O-ring (3).

Copyright © SECTION 21 - TRANSMISSION Use proper pliers to release the catch on the collar fastening the boot. Remove the collar (4).

Remove the protection boot (5).

Remove the 2 pins (7).


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Remove the bushing (9).


Remove the gearshift lever (6).

If disassembly is required, remove the pins (11) and separate the yokes from the shift rods. Make sure that you remember how the parts are assembled and which parts go together. Inspect all parts for burrs or excessive wear. Assembly is the reverse procedure of disassembly.

Copyright © SECTION 21 - TRANSMISSION Assembly Apply grease to the ball of the gearshift lever. Assemble the gearshift lever (6).

Check for the correct position of the control lever (6) according to the gearbox cover (2): - direct the recess (A) towards the straight side of cover (B); - the slots (C) aligned with the cover holes (D).


Assemble the bushing (9).

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Insert the pins (7) through the holes of the cover flange, so that they engage in the slots of the gearshift lever.

Assemble the protection boot (5) so that its end is correctly positioned over the pin ends. Be careful so that the pins do not fall out during this step.

Assemble the collar (4) on the protection. Use proper pliers to engage the collar block.

Copyright © SECTION 21 - TRANSMISSION Assemble and lubricate the O-ring (3) in the seat of the cover flange. Put the gearshift control assy behind the rear cover. Screw in and tighten the screws (1) to a tightening torque of 23 Nm (17 lbf·ft).

Insert the two pins (11) to lock the 3rd and 4th speed control yoke (13) and the 1st and 2nd speed control yoke (14).

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TROUBLESHOOTING FAULT The vehicle does not move.

POSSIBLE CAUSE

ACTION

Control valve supply problem.

Check and, if necessary, replace the control valves.

Damaged connections of transmission and vehicle wiring harness.

Repair and, if necessary, replace the wiring harness.

Oxidation in the contacts of the electric cables of the wiring harness.

Clean the contacts.

Interruption of the electric cable.

Replace the electric cable.

Damage to the solenoids/solenoid valves.

Replace the solenoids.

Damage to sensors.

Replace sensors.

Short circuits or bad contact.

Check and, if necessary, replace the fuses.

Incorrect oil level.

Restore the oil level.

Check for possible oil leaks.

Eliminate the leaks and restore the oil level.

Suction strainer restriction.

Clean the suction strainer.

Damaged oil pump.

Replace the oil pump.

Damaged oil pump pressure relief valve.


Damaged/restricted filter.

Replace the filter.

Damaged / stuck control valve.

Replace the control valve.

Damaged converter.

Replace the converter.

Oil temperature below 0 °C (32 °F).

Wait for the operating temperature to be reached (stall test).

Damaged rotary seal rings.

Replace the rotary seal rings.

Synchronizers damaged.

Replace the synchronizers.

Stuck shuttle lever.

Repair the shuttle lever.

Excessively worn-out clutch assembly. Repair and, if necessary, replace the clutch disc kit. Lack of motion transmission (broken gears, shafts, bearings, etc.).

Check, repair and, if necessary, replace.


FAULT

POSSIBLE CAUSE The brake does not release.

145

ACTION Check the general pressure of transmission. Check voltage. Check the operation of the solenoid valve. Check the mounting of the brake solenoid valve block after operating on the brake. After the above-described verifications, disassemble the brake cover and check the condition of the parts for unlocking/locking the brake (seal rings, belleville washers, brake disc deformation, etc.).

The vehicle has a reduced power transmission.

Overheating.

Incorrect oil temperature.


Transmission oil overheating.

Restore acceptable temperature values.

Incorrect operating pressures.

Check the hydraulic circuit and replace (oil pump, filters, control valve).

Damaged converter.




Worn-out clutch assembly.

Replace/repair.

4WD fails to engage.

Repair/replace the 4WD shaft assy.

Overheated solenoids/solenoid valves.

Replace.

Damage to sensors.

Replace sensors.

Damaged cooling system.

Repair the cooling system.

Dirty heat exchanger.

Clean the heat exchanger.

Unintentionally activated parking brake.

Deactivate the parking brake.

Excessive soil deposit on axle wheel hubs.

Clean the axle wheel hubs.

Seizure (broken gears, shafts, bearings, etc.).


Copyright © 146


FAULT

Wheel rotation with lifted vehicle.

Noise.

Irregular coupling.

POSSIBLE CAUSE

ACTION

Braking force external to transmission: axle operating problem.

Check and repair the axle.

Dragging of clutch discs.

Repair and, if necessary, replace the clutch discs.

Damaged converter.


Damaged oil thermostat.

Replace the oil thermostat.



Worn-out oil pump.




Low oil temperature (high oil viscosity).


Incorrect oil gradient.

Change oil and filters.

Damaged control valve.



Repair and, if necessary, replace the shuttle lever.

Damaged converter.


Damaged oil pump.


Ventilation/Cavitation.

Check the oil level. Check the oil gradient.



Worn-out clutch discs.

Replace the clutch discs.

Synchronizer coupling wear.

Replace the synchronizer coupling.

Damaged 4WD coupling assy.

Replace the 4WD coupling assy.

Damaged hydraulic control valve.

Replace the control valves.

Electric system fault.

Repair the electric system.



Damaged converter.




Overheating.

See “overheating”.

Damaged hydraulic system.

Repair the hydraulic system.


147

FAULT

POSSIBLE CAUSE

The gear remains engaged.

Damaged/stuck shuttle lever.








Damaged clutch assembly.

Repair and, if necessary, replace the clutch assembly.

Gearshift lever damaged.

Replace gearshift lever.



Damaged 4WD connection assy.


Hydraulic system fault.




Braking sensor fault.

Check and, if necessary, replace the braking sensors.



Gearshift lever damaged.

Replace the gearshift lever.



Lack of 4WD power transmission.

Gear fails to engage.

ACTION

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REPAIR TIMES The times are referred to average values of maintenance performed by skilled personnel in workshops equipped with all necessary fixtures for a proper execution of the required works. The repair and/or replacement times are indicated in minutes. We assume that the transmission assy has already been removed from the machine. ASSY

OPERATION

TIME (minutes)

Plugs and filters

Oil filter replacement

5

Oil pump

Oil pump replacement

20

Replacement of lubrication tube

5

Replacement of supply tube for solenoid valve of parking brake

5

Control valve replacement

15

Control valve overhauling

60

Solenoid valve replacement

10

PTO shaft replacement

60

Replacement of seal rings on input shaft

20

Half box replacement

80

Open, clean, close the half boxes

50

Replacement of shaft A / bearings

60

Overhauling of shaft A

150

Replacement of seal rings on shaft A

120

Replacement of shaft D / bearings

60

Replacement of shaft B

60

Overhauling/replacement of shaft C

150

Replacement of bearings of shaft B

60

Replacement of bearings of shaft C

60

Overhauling/replacement of shaft E

100

Shaft E

Replacement of bearings of shaft E

70

(only with 4WD models)

Replacement of seal rings

70

Gear/sleeve replacement

90

Gearshift lever replacement

20

Disc kit replacement

40

Brake overhauling/replacement

40

Lines

Control valve 4WD solenoid valve (only with 4WD models)

Transmission box

Shafts A and D

Shafts B and C

Gearshift control Parking brake


149

SPECIAL TOOLS PN CNH

DESCRIPTION

USE

2WD 4WD

380002211

Handle

To be used with the various pushers and buffers

380200190

Buffer

Assembly / disassembly of several bearings

380200197

Buffer

Assembly of bearings of shaft A

380200203

Buffer

Assembly of bearings of shaft B and C

380200207

Protection

Assembly of 4WD shaft seal ring

/

380200208

Protection

Assembly of 4WD shaft seal ring

/

380200213

Protection

Assembly of 4WD shaft cover seal ring

/

380200214

Calibrator

Assembly of seal ring on PTO shaft and 4WD shaft

380200215

Attachment

Disassembly / assembly of clutch

380200218

Buffer

Assembly of oil pump seal ring

380200224

Cover and shims

Assembly of seal ring on shaft A

380200225

Plunger


380001926

Protection

Clutch piston assembly

380200226

Buffer

Assembly of SAHR seal ring for parking brake

380200230

Buffer

Assembly of bearings of shaft D

380001933

Cover and shims


380001927

Calibrator


380001928

Plunger


380200246

Hook

Lifting of shafts B and C and of gear control yokes

380200257

Protection

Assembly of seal ring on PTO shaft

380200258

Tool

Disassembly / Assembly of snap ring on 4WD shaft

/

Copyright © 150


POWERSHIFT TRANSMISSION This transmission is used on powershift backhoe loader models 580ST - 590ST - 695ST.

TECHNICAL SPECIFICATIONS 4WD/2WS TRANSMISSION - POWERSHIFT (580ST - 590ST) Model ..................................................................................................................... CARRARO TLB2 MPB 4WD Type (4x4) ................................................................................................. 4 forward and 4 reverse travel gears Torque converter ratio .................................................................................................................................. 2.38 Transmission ratios: 1st gear .........................................................................forward travel 5.533:1








4WD/4WS TRANSMISSION - POWERSHIFT (695ST) Model ..................................................................................................................... CARRARO TLB2 MPB 4WS Type (4x4) ................................................................................................. 4 forward and 4 reverse travel gears Torque converter ratio .................................................................................................................................. 2.38 Transmission ratios: 1st gear .........................................................................forward travel 4.468:1









151

HYDRAULIC CONTROL VALVE 2/3 proportional solenoid valve specifications Absorption:.................................................................................................................................................. 10 W Protection degree:......................................................................................................................................IP69K Solenoid resistance:......................................................................................................... 7.25

[20 °C (68 °F)]

Power supply voltage:............................................................................................................................12 V DC

2/3 solenoid valve specifications Power supply voltage:............................................................................................................................12 V DC Absorption:........................................................................................................................ 1.68 A [20 °C (68 °F)] Protection degree:......................................................................................................................................IP69K Solenoid resistance:......................................................................................................... 7.14

[20 °C (68 °F)]

2/4 solenoid valve specifications Power supply voltage:............................................................................................................................12 V DC Absorption:........................................................................................................................ 1.68 A [20 °C (68 °F)] Protection degree:......................................................................................................................................IP69K Solenoid resistance:......................................................................................................... 7.14

Diagram A.

2/3 proportional solenoid 2nd - 4th speed actuation

B.

2/3 proportional solenoid reverse speed

C.

2/3 proportional solenoid forward speed

D.

2/3 proportional solenoid 1st - 3rd speed actuation

E.

2/3 solenoid valve 4WD engagement

F.

2/4 solenoid valve 2nd or 4th speed selection

G.

2/3 solenoid valve differential lock engagement

H.

2/4 solenoid valve 1st or 3rd speed selection

PS.

Supply pressure check port

HDL2. Differential lock engagement control port

[20 °C (68 °F)]

Copyright © 152


Copyright © SECTION 21 - TRANSMISSION DIMENSIONS 2WS

153

Copyright © 154 4WS


Copyright © SECTION 21 - TRANSMISSION HYDRAULIC DIAGRAM 2WS

155

Copyright © 156


REF.

DESCRIPTION

NOTES

1

Suction filter

2

Pump

3

Oil filter relief valve

23 bar (333 psi)

4

Filter

10 Nm (7.4 lbf·ft)

5

Torque converter

6

Oil cooler

7

Torque converter relief valve

8

Pressure regulator for sequential valve

9

Air breather

10

Forward gear pressure check port

11

Reverse gear pressure check port

12

Forward gear clutch

13

Reverse gear clutch

14

4WD clutch

15

HDL

16

Shaft lubrication inlet

17

Brake oil return port

18

Transfer oil return port

19

Main pressure check port

20

Pressure check port of 1st gear clutch

21

Pressure check port of 2nd gear clutch

22

1st gear clutch

23

2nd gear clutch

24

3rd gear clutch

25

4th gear clutch

26

Main shaft lubrication

27

Output shaft lubrication

28

Temperature thermostat

29

Parking brake lubrication

250 Nm (184.39 lbf·ft) 36 cm3/rev (2.20 in3/rev)

3.5 ÷ 5.5 bar (50 ÷ 80 psi)

Copyright © SECTION 21 - TRANSMISSION 4WS

157

Copyright © 158


REF.

DESCRIPTION

NOTES

1

Suction filter

2

Pump

3

Oil filter relief valve

23 bar (333 psi)

4

Spin-on filter

10 Nm (7.4 lbf·ft)

5

Torque converter

6

Oil cooler

7

Torque converter relief valve

8

Pressure regulator for sequential valve

9

Air breather

10


11


12

Forward gear clutch

13

Reverse gear clutch

14

4WD clutch

15

HDL

16

Shaft lubrication inlet

17

Brake oil return port

18

Transfer oil return port

19

Main pressure check port

20

Pressure check port of 1st gear clutch

21

Pressure check port of 2nd gear clutch

22

1st gear clutch

23

2nd gear clutch

24

3rd gear clutch

25

4th gear clutch

26

Main shaft lubrication

27

Output shaft lubrication

28

Temperature thermostat

29

Parking handbrake lubrication

250 Nm (184.39 lbf·ft) 36 cm3/rev (2.20 in3/rev)

3.5 ÷ 5.5 bar (50 ÷ 80 psi)


159

PORTS 2WS

REF.

DIMENSION

USE

1

7/8” - 14 UNF

Oil inlet from cooler

2

7/8” - 14 UNF

Oil outlet to cooler

3

9/16” - 18 UNF

Check port for torque converter input pressure

NOTES - MISCELLANEOUS

3 ÷ 9 bar (43.5 ÷ 130 psi) 13.5 ÷ 16.5 bar (196 ÷ 239 psi)

4

9/16” - 18 UNF


0.3 bar (4.3 psi) = maximum pressure in neutral position 13.5 ÷ 16.5 bar (196 ÷ 239 psi)

5

9/16” - 18 UNF

6


0.3 bar (4.3 psi) = maximum pressure in neutral position

Oil drain plug

7

9/16” - 18 UNF

8

9/16” - 18 UNF

9

Oil pressure delivery to differential lock

14 ÷ 17 bar (203 ÷ 246 psi)

Lubrication pressure check port (from cooler) 1 ÷ 5 bar (14.5 ÷ 72.5 psi) forward/reverse gear Oil outlet to brake tank

1 ÷ 5 bar (14.5 ÷ 72.5 psi) neutral position

9/16” - 18 UNF

Brake oil pressure delivery

14 ÷ 17 bar (203 ÷ 246 psi)

10

9/16” - 18 UNF

Oil return

11

9/16” - 18 UNF

Oil level check port

12

9/16” - 18 UNF

Oil main pressure check port

13

1/8” - BSP

Lubrication check port

14

1/8” - BSP

Check port of 1st gear

15

1/8” - BSP

Check port of 2nd gear

16

1/8” - BSP

Check port of 4th gear

14 ÷ 17 bar (203 ÷ 246 psi)

Copyright © 160


4WS

REF.

DIMENSION

USE

1

7/8” - 14 UNF

Oil inlet from cooler

2

7/8” - 14 UNF

Oil outlet to cooler

3

9/16” - 18 UNF

Check port for torque converter input pressure

NOTES - MISCELLANEOUS

3 ÷ 9 bar (43.5 ÷ 130 psi) 13.5 ÷ 16.5 bar (196 ÷ 239 psi)

4

9/16” - 18 UNF Forward gear pressure check port

0.3 bar (4.3 psi) = maximum pressure in neutral position 13.5 ÷ 16.5 bar (196 ÷ 239 psi)

5

9/16” - 18 UNF Reverse gear pressure check port

6

0.3 bar (4.3 psi) = maximum pressure in neutral position

Oil drain plug

7

9/16” - 18 UNF Oil pressure delivery to differential lock

8

9/16” - 18 UNF

9

9/16” - 18 UNF Brake oil pressure delivery

10

9/16” - 18 UNF Oil return

11

9/16” - 18 UNF Oil level check port

12

9/16” - 18 UNF Oil main pressure check port

13

1/8” - BSP

Lubrication check port

14

1/8” - BSP

Check port of 1st gear

15

1/8” - BSP

Check port of 2nd gear

16

1/8” - BSP

Check port of 4th gear

14 ÷ 17 bar (203 ÷ 246 psi)

Lubrication pressure check port (from cooler) 1 ÷ 5 bar (14.5 ÷ 72.5 psi) forward/reverse gear Oil outlet to brake tank

1 ÷ 5 bar (14.5 ÷ 72.5 psi) neutral position 14 ÷ 17 bar (203 ÷ 246 psi)

14 ÷ 17 bar (203 ÷ 246 psi)


161

CONTROLS

1. GEARSHIFT AND DIRECTION CONTROL LEVER: it is possible to select four forward and four rearward travel gears. The lever has 3 positions, according to which the travel direction is defined: F = forward travel N = idle/neutral R = reverse By turning the knob, instead, the following gears are selected: 1 = 1st gear 2 = 2nd gear 3 = 3rd gear 4 = 4th gear

2. KICKDOWN SWITCH: if the machine is in second gear and it is necessary to shift to the first gear to work with the loader attachment, activating the kickdown switch to a lower ration allows the machine to instantly shift from second to first gear. When the reverse travel is activated, transmission reverts to second gear. 3. TRANSMISSION DISCONNECT BUTTON (on loader attachment control lever)

Copyright © 162


KICKDOWN (QUICK SHIFTING TO LOWER GEAR RATIO) The kickdown function (2nd to 1st gear only) instantly increases the torque on the driving wheels and, hence, the digging power. For example when the loader is pushing into a pile and more torque is required at the wheels. This is achieved by an instant gearshift from 2nd to 1st gear by means of button (2).

1 TRANSMISSION DISCONNECTION The disconnect feature is useful when loading, for example; when pushing the loader into a pile and you have sufficient dirt in the bucket press the disconnect switch (3) which disengages the transmission and allows the full power of the engine to be directed to the hydraulic oil pump. Disconnection is available in 1st and 2nd gear. NOTE: transmission disconnection is selectable when the machine speed is lower than 5 km/h, by depressing the button on the loader lever, and remains active until the switch is released. 2

Copyright © SECTION 21 - TRANSMISSION LUBRICATION

1. Hole for filling and fastening of oil dipstick 2. Oil level plug 3. Oil drain plug 4. Breather

LEVEL CHECK The oil level check should be carried out with the engine running at low speed and at normal operating temperature. Move the machine to a level and firm ground. Raise the loader attachment and assemble the safety support strut. Place the backhoe attachment in the road travel position. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Open and raise the engine guard and lock it in opened position by means of the safety lock on the left-hand gas spring. Extract the dipstick (1), clean it with a clean cloth and completely insert it into the hose, then take it out again. If the oil level is below the mini mark, top up. Stop the engine. Unlock the safety lock and close the engine guard.

163

Copyright © 164


OIL CHANGE Move the machine to a level and firm ground. Raise the loader attachment and assemble the safety support strut. Place the backhoe attachment in the road travel position. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Stop the engine and remove the starter key. Open and raise the engine guard and lock it in opened position by means of the safety lock on the left-hand gas spring. Remove the dipstick (1). NOTE: change the oil while the transmission is still warm; the oil will flow more easily. Place a container with suitable capacity under the drain plug (2). Loosen and remove the drain plug (2). Let the transmission oil drain.

Re-install the drain plug (2). Fill with new oil of specified type through the dipstick hole. NOTE: transmission (4.57 gal).

oil

capacity

20.8

litres

Reassemble the dipstick (1). Check the oil level by means of the dipstick and, if necessary, add more oil. Drive the machine for a few minutes in first and second gear, then stop the engine. Check the oil level again by means of the dipstick and, if necessary, add more oil.

Copyright © SECTION 21 - TRANSMISSION GREASING Tecnolube POLYMER 400 grease Transmission oil

165

Copyright © 166


REMOVAL FROM MACHINE

1. Transmission

12. Dipstick tube

2. Anti-vibration

13. Dipstick

3. Left transmission support 4. Right transmission support


5. Washer

15. Washer


16. Torque converter

7. Washer

18. Plate


19. Snap ring

9. Washer 10. M12 nut


11. M8 x 25 screw [tightening torque 26 ÷ 31 Nm (19 ÷ 23 lbf·ft)]


17. Plate

20. Washer

Copyright © SECTION 21 - TRANSMISSION DISASSEMBLY AND ASSEMBLY Some of the following pictures could not exactly show your transmission, but the procedure is correct. TIGHTENING TORQUES AND APPLICATION OF SEALANTS / ADHESIVES A. Loctite 510 B. Loctite 542 C. Loctite 518 D. Loctite 638

167

Copyright © 168



169

Copyright © 170 Only 4WS


Copyright © SECTION 21 - TRANSMISSION PLUGS AND FILTERS

Disassembly Remove the oil drain plug (1) and drain the oil from the transmission.

171

Copyright © 172



Remove cover (3). Remove the oil filter (4) and the O-ring (5).

Unscrew and remove the oil filter (6). If necessary, remove the fitting (7).

Loosen and remove the valve (8).

Copyright © SECTION 21 - TRANSMISSION Check the valve (8). Clean the valve. If necessary, replace the O-rings (9) and (10).

If necessary, remove the breather (11).

NOTE: this port enables you to check the supply pressure for forward gear engagement. Remove the plug (12).

NOTE: this port enables you to check the supply pressure for reverse gear engagement. Remove the plug (13).

173

Copyright © 174


NOTE: this port enables you to check the lubrication pressure. Remove the plug (14).

Remove the revolution sensor (15).

Remove the oil thermostat (16).

Copyright © SECTION 21 - TRANSMISSION Assembly Assemble the revolution sensor (15). Tighten to the prescribed torque of 50 Nm (37 lbf·ft).

Assemble the oil thermostat (16). Tighten to the prescribed torque of 30 Nm (22 lbf·ft).

Assemble the plugs (12) and (13). Tighten to the prescribed torque of 30 Nm (22 lbf·ft).

Assemble and tighten the breather (11) by hand.

175

Copyright © 176


Clean the valve (8). Assemble the O-rings (9) and (10) onto the valve (8).

Assemble valve (8). Tighten to the prescribed torque of 28 Nm (21 lbf·ft).

Assemble fitting (7). Tighten to the prescribed torque of 50 Nm (37 lbf·ft).

Assemble the oil filter (6). Lubricate the gasket. Tighten clockwise until the gasket makes contact with its seat, then tighten further 2/3 of a turn.

Copyright © SECTION 21 - TRANSMISSION Assemble the O-ring (5) on the filter (4). Insert the filter (4).

Assemble the cover (3). Screw in the 2 screws (2) and tighten to the prescribed torque of 23 Nm (17 lbf·ft).

Assemble the oil drain plug (1). Tighten to the prescribed torque of 30 Nm (22 lbf·ft).

177

Copyright © 178


OIL PUMP

Disassembly Loosen and remove the screws (1). Mark the oil pump position with respect to the bell housing before loosening the screws.

Pull out the oil pump (2) by means of two levers (A).

Copyright © SECTION 21 - TRANSMISSION Remove the oil pump (2).

WARNING The O-ring can be damaged.


WARNING Do not disassemble the pump or its operation may be compromised.

If necessary, remove the seal ring (4).


179

Copyright © 180


Assembly Assemble the seal ring (4) onto the oil pump (2). Use tool 380200218. Lubricate the seal ring (4).


Before pump assembly (if new), check that the oil passage holes (between pump and half box) or the visual marks coincide.

Lubricate the seal ring (4) to keep it centred, in order to facilitate its introduction onto the oil pump.

Copyright © SECTION 21 - TRANSMISSION Lubricate the matching seat with the front half box. Assemble the oil pump (2).

Screw in and tighten the screws (1) to a tightening torque of 23 Nm (17 lbf·ft). Check that the mark on the oil pump and on the bell housing coincide.

181

Copyright © 182 HYDRAULIC CONTROL VALVE

Disassembly Disconnect cable (12).


Copyright © SECTION 21 - TRANSMISSION Drain the transmission oil. Disconnect the electric connections. Loosen all the fittings of the delivery pipes connected with the control valve (2). Loosen and remove the screws (1).

Remove the control valve (2).


Remove the pressure switch (4).

183

Copyright © 184


Place the control valve on a workbench. Loosen and remove the screws (5) of the valves.

Pull out the valves (6), (7) and (8) with a screwdriver.

Check the valves (6), (7) and (8).

Loosen and remove the valve (9).

Copyright © SECTION 21 - TRANSMISSION Check the valve (9). Clean the valve and, if necessary, replace the O-rings (10) and (11).

Assembly Clean the valve (9). Assemble the O-rings (10) and (11).

Assemble valve (9). Tighten to the prescribed torque of 25 ÷ 30 Nm (18 ÷ 22 lbf·ft).

185

Copyright © 186


Assemble the valves ON/OFF (6) and (7) and the proportional valves (8) by observing the shown positions.

Assemble the pressure switch (4).

Screw in and tighten the screws (5) to a tightening torque of 3 ÷ 4 Nm (2 ÷ 3 lbf·ft).

Copyright © SECTION 21 - TRANSMISSION Assemble the gasket (3).

Assemble the control valve (2).


187

Copyright © 188 HYDRAULIC SYSTEM LINES

Disassembly Drain the transmission oil. Remove the tube (1) (2nd gear).


Copyright © SECTION 21 - TRANSMISSION Remove the tube (2) (4th gear).

Remove the tube (3) (3rd gear).

Remove the tube (4) (1st gear).

Remove the tube (5) (4WD).

189

Copyright © 190 Remove the tube (6) (lubrication).

Remove the tube (7) (lubrication).


Copyright © SECTION 21 - TRANSMISSION Assembly Assemble the tube (7) (lubrication) by tightening the fittings to the tightening torque of 30 Nm (22 lbf·ft).

Assemble the tube (6) (lubrication) by tightening the fittings to the tightening torque of 30 Nm (22 lbf·ft).

Assemble the tube (5) (4WD) by tightening the fittings to the tightening torque of 30 Nm (22 lbf·ft).

Assemble the tube (4) (1st gear) by tightening the fittings to the tightening torque of 30 Nm (22 lbf·ft).

191

Copyright © 192


Assemble the tube (3) (3rd gear) by tightening the fittings to the tightening torque of 30 Nm (22 lbf·ft).

Assemble the tube (2) (4th gear) by tightening the fittings to the tightening torque of 30 Nm (22 lbf·ft).

Assemble the tube (1) (2nd gear) by tightening the fittings to the tightening torque of 30 Nm (22 lbf·ft).

Copyright © SECTION 21 - TRANSMISSION PARKING BRAKE

Disassembly Remove the oil drain plug (T) and drain the oil from the transmission.

193

Copyright © 194


Unscrew the screw (1). Use a screwdriver and 2 screws to lock the flange. Remove the screw (1) and the washer (2). Remove the flange (4) and the O-ring (3).

Loosen and remove the screws (6) and (7). Remove the brake (8) assembly. Remove the O-ring (9) from the brake (8).

Remove the seal ring (15).

WARNING The seal ring can be damaged. Remove the plug (5).

Remove the rings (10), the 5 brake discs (11) and the 5 counterdiscs (12).

Copyright © SECTION 21 - TRANSMISSION Remove the hub (13).

Only 4WS Remove the brake and the disc kit. Do not remove the plug (16).

Only 4WS Remove the screw (17), the washer (18) and the hub (19).

195

Copyright © 196


Assembly Assemble the hub (13).

Use a gauge to check that each counterdisc (12) and each brake disc (11) is flat. If necessary, replace them. If the brake discs (11) are nearly smooth, replace them. If the friction material is damaged or appears burned, replace it. Check the grooves for wear. Check counterdiscs (12) for pitting, scoring, or other damage. If necessary, replace them. If you will be using new brake discs, soak them in oil for at least an hour before assembly. If you are using the old friction discs, make sure that the contact surfaces are coated with oil before assembly, check the wear condition. If this is 50% compared to the nominal value, we suggest its replacement.

Brake disc kit Brake disc number

5

Counterdisc number

5

Nominal brake disc thickness Brake disc kit nominal thickness [with 163 kg (359.34 lbs) of load] Brake disc maximum wear (each side)

3.6 ± 0.05 mm (0.14 ± 0.002 in) 37.40 ÷ 37.60 mm (1.47 ± 1.48 in) 0.65 mm (0.02 in)

Copyright © SECTION 21 - TRANSMISSION Assemble the counterdisc (12), the brake disc (11) and the ring (10). Repeat this operation until the brake disc kit is complete.

Assemble the plug (5). Assemble the seal ring (15) onto the brake (8), use tool 380200226. Lubricate the seal ring (15).

Insert the O-ring (9) on the brake (8). Assemble the brake assy (8) on transmission. Screw in and tighten the screws (6) and (7) to the prescribed torque of 50 Nm (37 lbf·ft).

Assemble the flange (4) and the O-ring (3). Lubricate the O-ring (3). Assemble the washer (2) and the screw (1). Use a screwdriver and 2 screws to lock the flange. Tighten the screw (1) to a tightening torque of 139 Nm (102.5 lbf·ft).

197

Copyright © 198


Only 4WS Assemble the hub (19), the washer (18) and the screw (17). Tighten the screw (1) to a tightening torque of 139 Nm (102.5 lbf·ft).

Only 4WS Assemble the brake disc kit and the brake (8). Tighten the screws (6) and (7) to a tightening torque of 50 Nm (37 lbf·ft).

Copyright © SECTION 21 - TRANSMISSION TRANSMISSION BOX


199

Copyright © 200


Drain the transmission oil. Unscrew and remove the screw (1) for flange fastening (2).

If necessary, use a screwdriver and 2 screws to lock the flange.

Collect the washer (3).

Remove the flange (2) and the O-ring (4).

Copyright © SECTION 21 - TRANSMISSION Remove the seal ring (5).


Only 4WS Loosen and remove the screw (A) and the washer (B). If necessary, replace the O-ring (E). Remove the flange (D). If necessary, replace the seal ring (G). Loosen and remove the screws (C). Remove the hub (F).

Unscrew and remove the screws (6) for flange fastening (7).

Remove the flange (7).

201

Copyright © 202


Pull out the transmission shaft PTO (8).



Take out the bearing (11) with tool 380200190.

Copyright © SECTION 21 - TRANSMISSION Loosen and remove the screws (12) from the rear (13) and the front half box (14).

Insert a lever (L) in the special slot and remove the cover. NOTE: the surfaces are attached with some sealant.

If necessary, use a plastic hammer to facilitate the separation of the half box.

WARNING Do not lift the transmission shafts; the removal of the shafts from their housings can damage the seal rings.

Lift the front half box (14).

203

Copyright © 204


Remove the 4 O-rings (15).

Seal all oil recirculation holes with rubber plugs (T).

Assembly Clean the edge of the rear half box. Carefully verify the box and its inner components for the possible presence of debris (dirt, filings or burrs). Thoroughly clean all possible dirt.

WARNING Only after a careful inspection of the whole transmission, proceed with the re-assembly. Remove the old sealant from the mating surface of the rear half box by means of a proper scraper.

Copyright © SECTION 21 - TRANSMISSION We suggest the use of a sealant solvent.

Carefully clean the O-ring seats.

Degrease and dry accurately the mating surface of the rear half box. NOTE: we suggest the use of a proper solvent.

Apply sealant on the mating surface of the rear half box.

205

Copyright © 206


Spread the sealant uniformly.

Prevent the penetration of the sealant in the O-ring seats.

Carefully clean the O-ring seats.

Assemble the O-rings (15). Do not lubricate the O-rings.

Copyright © SECTION 21 - TRANSMISSION Place the 4 O-rings (15) into their seats with a buffer.

Assemble the front half box (14) on the rear one. Make sure that the bearings of the shafts go straight into the bores in the front box. Push the front half box onto the rear one.


Tighten the screws (12) to the rear half box (13) and to the front half box (14). Tighten the screws (12) to a tightening torque of 50 Nm (37 lbf·ft).

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Copyright © 208


Assemble the seal ring (5) on the output of the front shaft by means of tool 380200226.

Assemble the flange (2) and a new O-ring (4).

Assemble the washer (3) and tighten the screw (1).

Tighten the screw (1) to a tightening torque of 139 Nm (102.5 lbf·ft). Use a screwdriver and 2 screws to lock the flange.

Copyright © SECTION 21 - TRANSMISSION Assemble the bearing (11) on the transmission shaft PTO (8).


To assemble the seal ring (9) perform following operations by means of the listed tools in sequence: 380200257; 380200225; 380200214.


209

Copyright © 210


Smear a thin layer of sealant on the flange (7).

WARNING During flange assembly, the 2 holes for the oil passage (P) should coincide.


Only 4WS Assemble the hub (F). Screw in and tighten the screws (C) to the tightening torque of 50 Nm (37 lbf·ft). Assemble the seal ring (G) by means of tool 380200226. Assemble O-ring (E). Assemble the flange (D). Place the washer (B), screw in and tighten the screw (A) to the tightening torque of 139 Nm (102.5 lbf·ft).

Copyright © SECTION 21 - TRANSMISSION A, D SHAFTS

Disassembly Grab the shaft with the (A) pliers and pull out the shaft assy (D).

211

Copyright © 212


Shaft (A) If necessary, remove the seal ring (1).


Assemble a bearing separator under the gear (do not assemble the bearing separator between the gear and the bearing). Use a puller on the bearing separator and insert a shaft protector between the puller and the end of the input shaft. By means of puller which operates between separator and shaft protection, pull only until the bearing is free, otherwise the parts can be damaged.


Copyright © SECTION 21 - TRANSMISSION Remove the spacer (4).




213

Copyright © 214


Remove the pin (9).


Lift and remove the snap ring (11).


Copyright © SECTION 21 - TRANSMISSION Place a mark below the groove on the clutch bell.

Mark the snap ring (11), the discs (18) and the counterdiscs (17). These marks will be used as a reference during assembly.



215

Copyright © 216


Loosen the knobs of the threaded bars to clear the spring tension. Remove the upper part of tool 380200215.



Remove the piston (19) by blowing in compressed air through the delivery hole.

Copyright © SECTION 21 - TRANSMISSION If necessary, remove the seal ring (20) with the inner O-ring from the outside seat of the piston and the seal ring (21) with the relevant O-ring from the inner seat of the piston. To remove the rings it is necessary to cut them.

Turn the shaft. If necessary, remove the seal rings (22).


Remove the bearing (24) by means of a puller.

217

Copyright © 218


Remove the bearing (24) and the thrust washer (25).

Remove the gear (26) and the roller retainer (12).

For the disassembly of other parts, repeat the operations described previously.

Copyright © SECTION 21 - TRANSMISSION Check the seal ring grooves (large and small) for wear or damage. Check if the output shaft is worn or damaged. Check oil passages in the output shaft to be sure that they are open and free of foreign material. Check the ball bearings and the needle bearings for flat areas, pitting or other damage. If you are to re-use the clutch discs, observe the assembly order.

At each disassembly check with a gauge that the total thickness of the clutch discs remains in the wear limits; otherwise replace the clutch disc kit (18) with a new one. Verify that all clutch discs are free from burns, that the friction surfaces are not damaged and that the grooves of the friction surfaces are well outlined. Moreover, verify that the counterdiscs (17) are perfectly flat, without scrapes or pittings. In case any of the discs shows even just one of the above-mentioned faults, replace the clutch disc kit with a new one. If you are to use a new kit of clutch discs, let it soak into a bath of oil for at least one hour before its use. In any case, prior to assembling the clutch disc kit, lubricate the contact surfaces of the counterdiscs with oil.

Check that the hole of the input shaft on the rear half box does not show damages that could cause leaks when the clutch is assembled. Check that the grooves of the input shaft are not damaged by the steel discs.

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2WS forward - reverse gear clutch Disc number (each side)

6


6


A. Reverse B. Forward 1. Clutch disc (no. 6) 2. Clutch counterdisc (no. 3) 3. Clutch counterdisc (no. 3)

2.4 ± 0.05 mm (0.09 ± 0.002 in) 29.00 ÷ 29.20 mm (1.14 ± 1.15 in) 0.35 mm (0.01 in)


221

4WS forward gear clutch Disc number (each side)

7


7


A. Reverse B. Forward 1. Reverse clutch disc (no. 6) 2. Reverse clutch counterdisc (no. 2) 3. Reverse clutch counterdisc (no. 2) 4. Forward clutch disc (no. 7) 5. Forward clutch counterdisc (no. 3) 6. Forward clutch counterdisc (no. 4)

2.4 ± 0.05 mm (0.09 ± 0.002 in) 33.90 ÷ 34.10 mm (1.33 ± 1.34 in) 0.35 mm (0.01 in)

Copyright © 222


Shaft (D) Remove the bearing (16) from the shaft (D) by means of a puller.

Remove the bearing (37) from the shaft (D) by means of a puller.

Copyright © SECTION 21 - TRANSMISSION Assembly Shaft (A) Assemble the seal ring (20) with the relevant O-ring and the seal ring (21) with the relevant inner O-ring, respectively in the outer and inner seat of the piston.

Apply a thin film of oil on the seal rings.

Insert the piston (19) by means of tool (T) 380001926 to protect the seal rings (21).

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Insert the snap ring (14). NOTE: make sure that the snap ring (14) is correctly fitted into its seat.



Insert the thrust washer (8).

Insert the roller retainer (7).

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To assemble the clutch discs start with the gear (6) on the bench. Assemble the thrust washer (11) so that the reference mark on top of the plate, made during disassembly, is facing towards the gear.

Assemble the discs (18) and the counterdiscs (17) on the gear (6). The assembled clutch disc kit must contain 6 counterdiscs and 6 friction discs.

Use 2 screwdrivers to position the disc kit.


Copyright © SECTION 21 - TRANSMISSION Assemble the spacer (4).



NOTE: for clarity of the seal ring installation procedure, the following photos do not show the disc kit, gear, spacer, bearing, and snap ring installed on the input shaft.

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Insert the seal ring (1).

Assemble the 380200224 tool onto the input shaft with the chamfered end facing inwards.

Let tool 380200224 slide on the input shaft and above the spacer. The tool will stop in the correct position to install the seal ring in the groove.


Copyright © SECTION 21 - TRANSMISSION Assemble tool 380200225 over tool 380200224 and slide the seal ring until it reaches the groove in the shaft. Remove tools 380200224 and 380200225, the expander/protector and the spacer from the shaft.



Turn the shaft upside down to carry out the operations described previously. Lubricate the thrust washer (25). Assemble the thrust washer so that the notch in the inner edge fits over the pin. Make sure that the side with the oil grooves is down.

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Heat the bearing (24) to 80 ÷ 100 °C (176 ÷ 212 °F). By means of tool 380200197 place the bearing (24) onto the input shaft until it makes contact with the thrust washer.


Assemble the snap rings and place the spacer in the protection (tool 380001933).

Place tool 380001933 on the shaft. The tool will stop in the correct position to install the seal ring in the groove.

Copyright © SECTION 21 - TRANSMISSION Heat the seal ring to 60 ÷ 80 °C (140 ÷ 176 °F) for 5 minutes. Assemble the seal ring on tool 380001933.

Assemble tool 380001928 over tool 380001933 and slide the seal ring until it reaches the groove in the shaft. Remove tools 380001928 and 380001933.

Assemble the end of tool 380001927 with the deep chamfer onto the shaft and over the seal ring. Use a back and forth twisting motion to allow the seal compressor to slip over the top of the seal ring and seat this latter into the groove. Be careful not to damage the seal ring. After the seal ring is seated in the groove, remove the seal compressor from the shaft.


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In order to insert the other 3 rings, repeat the operations described previously, by means of following spacer rings: 380001933 for the 2nd ring; 380001933 for the 3rd ring; 380001933 for the 4th ring.

1. Lubrication oil passage 2. Forward gear clutch passage 3. Reverse gear clutch passage 4. Forward gear engagement 5. Forward gear disc kit 6. Reverse gear disc kit 7. Reverse gear engagement 8. Input shaft Apply compressed air of approximately 6 bar (87 psi) to the forward clutch passage. Listen for the forward gear piston to move and to lock the relevant disc kit. Try to shift the forward travel gear. It must not turn on the input shaft. Try to shift the reverse travel gear. It must turn freely on the input shaft. If the clutches do not work correctly, disassemble them to find the problem.

Copyright © SECTION 21 - TRANSMISSION Carry out the check procedure of the clutch disc kit play on both sides of the clutch. Position the shaft on a suitable support (S) and apply load F on the counterdisc (11) surface by means of a proper buffer (T), as shown. This operation clears any possible play.

To check the backlash, supply the piston chamber with compressed air at 6 bar (87 psi) and verify the actual stroke “X” with a dial indicator. Determine clearance “X”.

Only for 2WS input shaft The piston stroke (19) and (38) must be such to ensure a play corresponding to X = 1.60 ÷ 2.45 mm (0.06 ÷ 0.10 in) If the distance is not within specification, the clutch is probably wrongly installed. Turn the clutch shaft upside down and repeat the operation for the other clutch disc kit.

Only for 4WS input shaft The piston stroke (19) and (38) must be such to ensure a play corresponding to X = 1.60 ÷ 2.45 mm (0.06 ÷ 0.10 in) Y = 1.90 ÷ 2.75 mm (0.07 ÷ 0.11 in) If the distance is not within specification, the clutch is probably wrongly installed. Turn the clutch shaft upside down and repeat the operation for the other clutch disc kit.

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Shaft (D) Assemble the bearing (16) on shaft (D) by means of tool 380200230.

Assemble the bearing (37) on shaft (D) by means of tool 380200230.

Lubricate the shaft seat (A).

Assemble shaft (D) and shaft (A). The operation is correct only if the 2 shafts are fitted at the same time.

Copyright © SECTION 21 - TRANSMISSION SHAFT B

Disassembly Unscrew and remove the screws (28) and remove the 4WD oil bulkhead (29).

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Assemble on the rear end of the shaft (C) the hub (27) and tool 380200256.

Lift the 3 shafts (B), (C) and (E) simultaneously by means of tool 380200239.

Do not remove the oil bulkhead (P) and the screw (V).

Remove the seal rings (1) and (2).

WARNING The seal rings can be damaged.

Copyright © SECTION 21 - TRANSMISSION Remove the bearing (3) and the gear (4) by means of a puller.

Remove the bearing (3) and the gear (4).



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Remove the roller retainer (7) and the thrust washer (13).

Remove the pin (24) and the spacer (14).

Copyright © SECTION 21 - TRANSMISSION Push the thrust washer (10) slightly.


Remove the thrust washer (10) by means of 2 screwdrivers.


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Copyright © SECTION 21 - TRANSMISSION Remove the sleeve (18).




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Check the seal ring grooves (large and small) for wear or damage. Check if the output shaft is worn or damaged. Check oil passages in the output shaft to be sure that they are open and free of foreign material. Check the ball bearings and the needle bearings for flat areas, pitting or other damage. If you are to re-use the clutch discs, observe the assembly order.

At each disassembly check with a gauge that the total thickness of the clutch disc kit remains within the wear limits; otherwise replace the clutch disc kit (11) with a new one. Verify that all clutch discs are free from burns, that the friction surfaces are not damaged and that the grooves of the friction surfaces are well outlined. Moreover, verify that the counterdiscs (12) are perfectly flat, without scrapes or pittings. In case any of the discs shows even just one of the above-mentioned faults, replace the clutch disc kit with a new one. If you are to use a new kit of clutch discs, let it soak into a bath of oil for at least one hour before its use. In any case, prior to assembling the clutch disc kit, lubricate the contact surfaces of the counterdiscs with oil.


243


2nd gear clutch Disc number (each side)

8


8

Rated thickness of disc Disc kit nominal thickness [with 163 kg (359.34 lbs) of load]

2.0 ± 0.05 mm (0.08 ± 0.002 in) 30.50 ÷ 30.70 mm (1.20 ÷ 1.21 in)


0.20 mm (0.008 in)

Pack maximum wear (each side)

3.2 mm (0.126 in)

Assembly Assemble the bearing (25) with tool 380200190.

Assemble the seal ring (26). In order to fit the ring (26), repeat the following operations by means of spacer ring 380200224.

Copyright © 244


Assemble the seal ring (20) with the relevant inner O-ring and the snap ring (21) with the relevant inner O-ring, respectively in the outer and inner seat of the piston.

Apply a thin film of oil on the seal rings recently fitted.

Insert the piston (19) by means of tool 380001926 to protect the seal rings (21).


Copyright © SECTION 21 - TRANSMISSION Assemble the spring (17) and the cover (16).




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Assemble the disc kit.

Assemble the spacer (14) and the pin (24).

Insert the thrust washer (13) and the roller retainer (7).

Assemble the thrust washer (10) and push it to end stroke on disc kit.


Supply compressed air at low pressure to the delivery hole to push the thrust washer (10) against the snap ring (9) and align the disc teeth.

Assemble the gear (8) by paying attention not to let it slide to stroke end.


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Assemble the thrust washer (6) and the snap ring (5).

Assemble the gear (4) paying attention to direct the protruding end of the groove towards the clutch and the bearing (3). Use tool 380200203.


1. Lubrication oil passage 2. Oil passage for 2nd gear clutch 3. 2nd gear engagement 4. 2nd gear clutch disc kit 5. Input shaft

Try to turn the 2nd travel gear. It must turn on the input shaft. Apply compressed air at approximately 6 bar (87 psi) to the 2nd gear clutch passage. Listen for the 2nd gear piston to move and to lock the related clutch disc kit. Try to shift the 2nd travel gear. It must not turn on the input shaft. If the clutch does not work correctly, disassemble it to find the problem. Carry out the check procedure of the clutch disc kit backlash on both sides of the FWD-REV-clutch. Position the shaft on a suitable support and apply load F on the counterdisc (10) surface by means of a proper buffer. This operation clears any possible play.

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To check the backlash, supply the piston chamber (19) with compressed air at 6 bar (87 psi) and verify the actual stroke “X” with a dial indicator. Determine clearance “X”.

Only for 2WS input shaft The piston stroke (19) must be such to ensure a play corresponding to: X = 2.20 ÷ 3.05 mm (0.09 ÷ 0.12 in) If the distance is not within specification, the clutch is probably wrongly installed.

Insert the seal rings (1) and (2). In order to insert the seal rings, repeat the following operations by means of: - spacer 380200240 for 1st and 2nd ring; - pusher 380200242 and compressor 380200241.

Assemble the bulkhead (29) and tighten the screws (28).

Copyright © SECTION 21 - TRANSMISSION SHAFT C

Disassembly Unscrew and remove the screws (V1) to detach the 4WD oil bulkhead (P1).

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Assemble on the rear end of the shaft (C) the hub (61) and tool 380200256.


Do not remove the oil bulkhead (P2) and the screw (V2).

Remove tool 380200256 and sleeve (62).

Copyright © SECTION 21 - TRANSMISSION Remove the bearing (58) by means of a puller.



Overturn the assembly. Push the thrust washer (39) downwards.

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Remove the disc kit (40).

Lower the cover (42) in order to allow the extraction of the snap ring (41) by means of tool 380200215.


Remove the snap ring (41), the cover (42) and the spring (43).


If necessary, remove the seal ring (45) with the relevant O-ring from the outer seat of piston (44).

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If necessary, remove the seal ring (53) with the relevant O-ring from the gear seat (54).

Remove the gear (37) by means of a puller.

Remove the 2 bushings (47) and (56), the 2 roller retainers (46) and (55) and the spacer (50). Verify the condition of the removed components (46), (47), (50), (55) and (56).

Remove the O-rings (48) and (52) from the bushing (50).

Copyright © SECTION 21 - TRANSMISSION Verify the wear condition of the seal rings (49) and (51). If necessary, cut the seal rings (49) and (51) to remove them from bushing (50).



Remove the thrust washer (31). Remove the feather (32).

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Lower the counterdisc (33) slightly to release the snap ring (34).




Copyright © SECTION 21 - TRANSMISSION Remove the pin (22).




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Pull out the piston (26) from its seat by blowing in compressed air through the delivery hole.

Remove the bushing (27) and the piston (26).


Copyright © SECTION 21 - TRANSMISSION Overturn the shaft (23). Remove the seal rings (16), (17), (18) and (19) by cutting them.




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Remove the roller retainer (7) and the thrust washer (8).


Remove the roller retainer (7) and the thrust washer (8). Remove the feather (22).

Slightly lower the thrust washer (5) to release the snap ring (4).

Copyright © SECTION 21 - TRANSMISSION Remove the snap ring (4).




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Pull out the piston (13) from its seat by blowing in compressed air through the delivery hole.

Copyright © SECTION 21 - TRANSMISSION Remove the bushing (12) and the piston (13).


Check the seal ring grooves (large and small) for wear or damage. Check if the output shaft is worn or damaged. Check oil passages in the output shaft to be sure that they are open and free of foreign material. Check the ball bearings and the needle bearings for flat areas, pitting or other damage.

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At each disassembly check with a gauge that the total thickness of the clutch discs remains in the wear limits; otherwise replace the clutch disc kit (B) with a new one. Verify that all clutch discs are free from burns, that the friction surfaces are not damaged and that the grooves of the friction surfaces are well outlined. Moreover, verify that the counterdiscs (A) are perfectly flat, without scrapes or pittings. In case any of the discs shows even just one of the above-mentioned faults, replace the clutch disc kit with a new one. If you are to use a new kit of clutch discs, let it soak into a bath of oil for at least one hour before its use. In any case, prior to assembling the clutch disc kit, lubricate the contact surfaces of the counterdiscs with oil. Check that the hole of the input shaft on the rear half box does not show damages that could cause leaks when the clutch is assembled. Check that the grooves of the input shaft are not damaged by the steel discs.


267

1st gear clutch Disc number (each side)

6


6


2.20 ± 0.05 mm (0.09 ± 0.002 in)

Disc kit nominal thickness [with 163 kg (359.34 lbs) of load]

27.50 ÷ 27.70 mm (1.08 ÷ 1.09 in)


0.15 mm (0.006 in)


1.8 mm (0.071 in)

3rd gear clutch Disc number (each side)

8


8


2.00 ± 0.05 mm (0.08 ± 0.002 in)


30.50 ÷ 30.70 mm (1.20 ÷ 1.21 in)


0.20 mm (0.008 in)


3.2 mm (0.126 in)

4th gear clutch Disc number (each side)

4


4


2.00 ± 0.05 mm (0.08 ± 0.002 in)


15.90 ÷ 16.10 mm (0.62 ÷ 0.63 in)


0.20 mm (0.008 in)


1.6 mm (0.063 in)

Copyright © 268


Assembly Assemble the seal ring (53) and the relevant O-ring on gear (54) by means of tool 380200248. Assemble the O-ring (52).

Adjust the seal ring (53) by means of tool 380200250.

Assemble the seal ring (45) and the relevant O-ring on piston (44).

Apply a thin film of grease on the outer edge and in the inner part of the piston (44) and fit it to the gear (54).

Copyright © SECTION 21 - TRANSMISSION Insert the spring (43), the cover (42) and the snap ring (41).


Insert the snap ring (41). Make sure that the snap ring (41) is correctly fitted into its seat.


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Insert the kit (40) and the thrust washer (39) into the gear (54).

Assemble the snap ring (38) making sure it is correctly seated.

Assemble the seal ring (25) with the relevant O-ring and the snap ring (24) with the relevant O-ring, respectively in the outer and inner seat of the piston (26).


Copyright © SECTION 21 - TRANSMISSION Insert the piston (26) by means of tool 380001926 to protect the seal rings.




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Insert the thrust washer (31) on the shaft (23). Apply a thin film of grease under the thrust washer (31) to prevent its falling when overturning the shaft.

Copyright © SECTION 21 - TRANSMISSION Assemble the thrust washer (31) by inserting it on pin (22).

Assemble the feather (22) and the thrust washer (31). Apply a thin film of grease under the thrust washer (31) to prevent its falling when overturning the shaft.

Insert the disc and counterdisc kit (32) onto the main shaft (23).

Assemble the roller retainer (36) and the thrust washer (33).

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Supply compressed air at low pressure into hole (a) to push the thrust washer (33) against the snap ring (34).

Assemble the gear (35) by paying attention not to let it slide to stroke end.

Insert the gear (37) on the shaft (23).

Copyright © SECTION 21 - TRANSMISSION Insert the gear (54) on the shaft (23).

Assemble the bushing (47) and the bearing (46) with tool 380200190.

Assemble the O-rings (48) and (52) on the bushing (50).

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Assemble new seal rings (49) and (51) on bushing (50) by means of tools 380200251, 380200252 and 380200253.

Assemble the bushing (50) and the shaft (23) with tool 380200190. The reference marks must be directed upwards.

Assemble the bushing (56) and the bearing (55) with tool 380200190.

Copyright © SECTION 21 - TRANSMISSION Assemble the spacer (57).

Assemble the bearing (58) with tool 380200190.

Assemble the hub (61) and tool 380200256.

Turn the shaft. Assemble the O-ring with relevant ring (14) in the outer seat of piston (13). Assemble the O-ring with relevant ring (15) in the inner seat of piston (13).

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Insert the piston (13) by means of tool 380001926 to protect the seal rings.



Copyright © SECTION 21 - TRANSMISSION Lower the cover (10) by means of tool 380200215.




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Insert the disc kit (6) on the shaft (23).

Assemble the thrust washer (5).


Supply compressed air at low pressure into the supply hole to push the thrust washer (5) against the snap ring (4).

Copyright © SECTION 21 - TRANSMISSION Assemble the thrust washer (8) and the roller retainer (7).

Assemble the feather (22), the thrust washer (8) and the roller retainer (7).



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Assemble the seal rings (16), (17), (18) and (19) by means of tool 380200224.


283

1. 1st gear clutch oil passage 2. 3rd gear clutch oil passage 3. 4th gear clutch oil passage 4. 3rd gear engagement 5. 3rd gear disc kit 6. 4th gear disc kit 7. 4th gear engagement 8. 1st gear engagement 9. 1st gear disc kit 10. Main shaft 11. Lubrication oil passage

Check that all gears turn freely on main shaft. Apply compressed air at approximately 6 bar (87 psi) to the 1st gear clutch passage. Listen for the 1st gear piston to move and to lock the related clutch disc kit. Try to shift the 1st travel gear. It must not turn on the main shaft. If the clutch does not work correctly, disassemble it to find the problem. Apply compressed air at approximately 6 bar (87 psi) to the 3rd gear clutch passage.

Listen for the 3rd gear piston to move and to lock the related clutch disc kit. Try to shift the 3rd travel gear. It must not turn on the main shaft. If the clutch does not work correctly, disassemble it to find the problem. Apply compressed air at approximately 6 bar (87 psi) to the 4th gear clutch passage. Listen for the 4th gear piston to move and to lock the related clutch disc kit. Try to shift the 4th travel gear. It must not turn on the main shaft.

If the clutch does not work correctly, disassemble it to find the problem.

Copyright © 284


Carry out the check procedure of the clutch disc kit play. Position the shaft on a suitable support and apply load F on the surface of the clutch counterdisc by means of a proper buffer (T). This operation clears any possible play.

To check the backlash, supply the piston chamber (26) with compressed air at 6 bar (87 psi) and verify the actual stroke “X” with a dial indicator. Determine clearance “X”.

The piston stroke (26) must be such to ensure a play corresponding to: X = 0.5 ÷ 1.95 mm (0.020 ÷ 0.077 in) If the distance is not within specification, the clutch is probably wrongly installed.

The piston stroke (13) must be such to ensure a play corresponding to: X = 2.20 ÷ 3.05 mm (0.09 ÷ 0.12 in) If the distance is not within specification, the clutch is probably wrongly installed.

Copyright © SECTION 21 - TRANSMISSION The piston stroke (44) must be such to ensure a play corresponding to: X = 1.725 ÷ 2.375 mm (0.068 ÷ 0.093 in) If the distance is not within specification, the clutch is probably wrongly installed.

Hook the 3 shafts (B), (C) and (E) by means of tool 380200239. Lift the shafts (B), (C) and (E) at the same time and insert the assy into the half box.

Assemble the bulkhead (P1) and tighten the screws (V1).

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E SHAFT (Only for 2WS)

* = 4WD shaft set

Disassembly Unscrew and remove the screws to detach the 4WD oil bulkhead.

Copyright © SECTION 21 - TRANSMISSION Assemble on the rear end of the shaft (C) the hub and tool 380200256.




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Remove the bearings (21) and (1) by means of a puller. Remove the spacer (20).



Overturn the shaft. Press the belleville washers and remove the snap ring (2) by means of tool 380200258.

Copyright © SECTION 21 - TRANSMISSION Remove the shims (3) and the thrust washer (4).

Remove the belleville washers (5) and the spacer (6).


Remove the thrust washer (16) and the disc and counterdisc kit (15).

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Remove the counterdisc (14).

Take out the piston (8).

Remove the inner (7) and outer O-ring (9) from the piston (8).

Remove the pins (10) and the O-rings (11).


291



Check that the hole of the input shaft on the rear half box does not show damages that could cause leaks when the clutch is assembled. Check that the grooves of the input shaft are not damaged by the steel discs. 4WD clutch Disc number (each side)

9


9


2.00 ± 0.05 mm (0.08 ± 0.002 in)


33.80 ÷ 34.00 mm (1.33 ÷ 1.34 in)


0.15 mm (0.006 in)


2.7 mm (0.106 in)

Copyright © 292


Assembly Insert the inner O-ring (7) and the outer O-ring (9) on the piston (8).

Insert the O-rings (11) on the related pins (10).

Insert the pins (10) on the piston (8).

Apply a thin film of grease on the O-rings and position the pins on piston (8) in order to match the holes of the output shaft.

Copyright © SECTION 21 - TRANSMISSION Overturn the shaft (12) and insert the piston (8).

Insert the counterdisc (14) with the chamfer downwards into the shaft (12).

Assemble the disc and counterdisc kit starting with a counterdisc (A) followed by a disc (B).

Assemble the thrust washer (16) on the shaft (12).

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Assemble the roller retainer (19) and the spacer (20).


Copyright © SECTION 21 - TRANSMISSION Turn the shaft (12). Make sure that the disc, counterdisc kit and the piston are correctly seated.

Pre-assemble the spacer (6), the thrust washer (4) and the snap ring (2).

With a thickness gauge determine the value of “X” between the thrust washer (4) and the snap ring (2).

To value “X” subtract the fixed measure “S1” of 1.80 mm (0.071 in) corresponding to the piston stroke. The resulting measure “S” corresponds to the height of the shim that must be inserted between the thrust washer (4) and the snap ring (2). S = X - S1 = X - 1.80 mm (0.071 in)

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Choose the shim with value “S” from the shim range available. NOTE: in any case, choose the shim ensuring a piston stroke of 1.70 ÷ 1.90 mm (0.067 ÷ 0.075 in). SHIM RANGE Shims mm (in)

0.1 (0.004)

0.3 (0.012)

0.5 (0.02)

Remove the thrust washer (4) and the snap ring (2).

Insert the belleville washers (5). Check the proper orientation of the belleville washers (5).

Assemble the thrust washer (4) and the shims (3) with size “S” previously calculated.

Copyright © SECTION 21 - TRANSMISSION Press the belleville washers and fit the snap ring (2) by means of tool 380200275. The springs can cause damages to persons if the snap ring is not assembled correctly.


Assemble the seal rings (22) and (23). Use tool 380200224.

Use tool 380200223 to check piston operation and verify correct adjustment.

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In order to check the sealing of rings (7) and (9), put the piston chamber under pressure with oil at 10 bar (145 psi) and verify with a dial gauge that the actual stroke is 1.70 ÷ 1.90 mm (0.067 ÷ 0.075 in).

1. 4WD oil passage 2. 4WD gear 3. 4WD lubricant oil passage 4. Shaft 5. Belleville washers

Apply compressed oil pressure of approximately 10 bar (145 psi) to the 4WD clutch passage. Listen for the piston to move and to unlock the related clutch disc kit. The belleville washers compress themselves. Try to shift the 4WD gear. It must turn freely on the 4WD shaft. If the clutches do not work correctly, disassemble them to find the problem.

Copyright © SECTION 21 - TRANSMISSION Lift the 3 shafts (B), (C) and (E) at the same time and insert the assy into the half box by means of tool 380200239.

Assemble the bulkhead and tighten the screws.

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E SHAFT (Only for 2WS)

* = 4WD shaft set


Copyright © SECTION 21 - TRANSMISSION Assemble on the rear end of the shaft (C) the hub and tool 380200256.




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Remove the bearings (1) and (24) by means of a puller. Remove the spacer (23).




Copyright © SECTION 21 - TRANSMISSION Overturn the shaft (13). Press the belleville washers (5) and remove the snap ring (2) by means of tool 380200258.



Overturn the shaft (13). Remove the bell housing assy from the shaft.

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Remove the thrust washer (18) and the disc and counterdisc kit (15).

Remove the 4WD disc and counterdisc kit (17).

Copyright © SECTION 21 - TRANSMISSION Remove the counterdisc (16).

Take out the piston (8) by means of pins (10).



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4WD clutch Disc number (each side)

9


9


2.00 ± 0.05 mm (0.08 ± 0.002 in)


33.80 ÷ 34.00 mm (1.33 ÷ 1.34 in)


0.15 mm (0.006 in)


2.7 mm (0.106 in)

Copyright © SECTION 21 - TRANSMISSION Assembly Insert the inner O-ring (7) and the outer O-ring (9) on the piston (8).


Insert the pins (10) on the clutch piston (8).

Apply a thin film of grease on the O-rings and position the pins on piston (8) in order to match the holes of the output shaft (12).

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Overturn the bell housing (12) and insert the piston (8).

Insert the brake counterdisc (16) with the chamfer downwards into the bell housing (12).

Assemble the disc and counterdisc kit (17) starting with a counterdisc (A) followed by a disc (B).




Assemble the shaft (13).

Turn the shaft (13) and the bell housing (12). Make sure that the disc and counterdisc kit and the piston are correctly seated.

309

Copyright © 310




To value “X” subtract the fixed measure “S1” of 1.80 mm (0.071 in) corresponding to the piston stroke. The resulting measure “S” corresponds to the height of the shim that must be inserted between the thrust washer (4) and the snap ring (2). S = X - S1 = X - 1.80 mm (0.071 in)


0.1 (0.004)

0.3 (0.012)

0.5 (0.02)

Copyright © SECTION 21 - TRANSMISSION Remove the thrust washer (4) and the snap ring (2).

Insert the belleville washers (5).

Check the proper orientation of the belleville washers (5).


311

Copyright © 312


Press the belleville washers and fit the snap ring (2) by means of tool 380200275. The springs can cause damages to persons if the snap ring is not assembled correctly.




Copyright © SECTION 21 - TRANSMISSION Assemble the roller retainer (22) and the spacer (23).


Assemble the seal rings (25) and (26) by means of tool 380200224.

Use tool 380200223 to check piston operation and verify correct adjustment.

313

Copyright © 314


In order to check the sealing of the rings, put the piston chamber under pressure with oil at 10 bar (145 psi) and verify with a dial gauge that the actual stroke is 1.70 ÷ 1.90 mm (0.067 ÷ 0.075 in).

1. 4WD oil passage 2. 4WD gear 3. 4WD lubricant oil passage 4. Shaft 5. Belleville washers

Apply compressed oil pressure of approximately 10 bar (145 psi) to the 4WD clutch passage. Listen for the piston to move and to unlock the related clutch disc kit. The belleville washers compress themselves. Try to shift the 4WD gear. It must turn freely on the 4WD shaft. If the clutches do not work correctly, disassemble them to find the problem.

Copyright © SECTION 21 - TRANSMISSION Lift the 3 shafts (B), (C) and (E) at the same time and insert the assy into the half box by means of tool 380200239.


315

Copyright © 316


E SHAFT (Only 4WS)


Copyright © SECTION 21 - TRANSMISSION Lift the 3 shafts (B), (C) and (E) simultaneously by means of tool 380200239.


Remove the seal rings (24), (25) and (26).


317

Copyright © 318



Remove the snap ring (19). Remove the bearing (19) by means of a puller.

Remove the snap ring (16). Remove the thrust washer (18) and the disc and counterdisc kit (14).

Remove the counterdisc (13).

Copyright © SECTION 21 - TRANSMISSION Overturn the shaft (17). Press the belleville washers (5) and remove the snap ring (2) by means of tool 380200258.



Remove the bell housing (12) from the shaft (17). Remove the O-ring (18).

319

Copyright © 320


Take out the piston (8) by means of pins (10).





321

At each disassembly check with a gauge that the total thickness of the clutch discs remains in the wear limits; otherwise replace the clutch disc kit with a new one. Verify that all clutch discs (b) are free from burns, that the friction surfaces are not damaged and that the grooves of the friction surfaces are well outlined. Moreover, verify that the counterdiscs (a) are perfectly flat, without scrapes or pittings. In case any of the discs shows even just one of the above-mentioned faults, replace the clutch disc kit with a new one. If you are to use a new kit of clutch discs, let it soak into a bath of oil for at least one hour before its use. In any case, prior to assembling the clutch disc kit, lubricate the contact surfaces of the counterdiscs with oil.

Check that the hole of the input shaft on the rear half box does not show damages that could cause leaks when the clutch is assembled. Check that the grooves of the input shaft are not damaged by the steel discs. 4WD clutch Disc number (each side)

9


9


2.00 ± 0.05 mm (0.08 ± 0.002 in)


33.80 ÷ 34.00 mm (1.33 ÷ 1.34 in)


0.15 mm (0.006 in)


2.7 mm (0.106 in)

Copyright © 322


Assembly Insert the inner O-ring (7) and the outer O-ring (9) on the piston (8).


Insert the pins (10) on the piston (8).

Apply a thin film of grease on the O-rings and position the pins on piston (8) in order to match the holes of the output shaft (12).

Copyright © SECTION 21 - TRANSMISSION Overturn the bell housing (12) and insert the piston (8).

Insert the brake counterdisc (13) with the chamfer downwards into the clutch bell housing (12).

Assemble the disc and counterdisc kit (14) starting with a counterdisc (A) followed by a disc (B).


323

Copyright © 324


Assemble the O-ring (18) on the shaft (17). Turn the shaft (17) on the bell housing (12).

Turn the shaft (13) and the bell housing (12). Make sure that the disc, counterdisc kit and the piston are correctly seated.



Copyright © SECTION 21 - TRANSMISSION To value “X” subtract the fixed measure “S1” of 1.80 mm (0.071 in) corresponding to the piston stroke. The resulting measure “S” corresponds to the height of the shim that must be inserted between the thrust washer (4) and the snap ring (2). S = X - S1 = X - 1.80 mm (0.071 in)


0.1 (0.004)

0.3 (0.012)

0.5 (0.02)

Remove the thrust washer (4) and the snap ring (2).

325

Copyright © 326


Insert the belleville washers (5).

Check the proper orientation of the belleville washers (5).


Press the belleville washers and fit the snap ring (2) by means of tool 380200275. The springs can cause damages to persons if the snap ring is not assembled correctly.

Copyright © SECTION 21 - TRANSMISSION Turn the shaft (17) and the bell housing (12). Assemble the bearing (19) with tool 380200229. Assemble the snap ring (20).




327

Copyright © 328


Fitting diagram of bearing (23).

Assemble the seal rings (24), (25) and (26).

Use tools 380200264, 380001927 and 380001928.

Fitting diagram of tool (T) 380200264.

Copyright © SECTION 21 - TRANSMISSION Use tool 380200265 to check piston operation and verify correct adjustment.

In order to check the sealing of rings (7) and (9), put the piston chamber under pressure with oil at 10 bar (145 psi) and verify with a dial gauge that the actual stroke is 1.70 ÷ 1.90 mm (0.067 ÷ 0.075 in).

1. 4WD oil passage 2. 4WD gear 3. Bearing lubrication 4. Shaft 5. Belleville washers 6. Bearing

329

Copyright © 330


Apply compressed oil pressure of approximately 10 bar (145 psi) to the 4WD clutch passage. Listen for the piston to move and to unlock the related clutch disc kit. The belleville washers compress themselves. Try to shift the 4WD gear. It must turn freely on the 4WD shaft. If the clutches do not work correctly, disassemble them to find the problem. Lift the 3 shafts (B), (C) and (E) at the same time and insert the assy into the half box by means of tool 380200239.



331

TROUBLESHOOTING FAULT The vehicle does not move.

POSSIBLE CAUSE

ACTION

Control valve supply problem.

Check and, if necessary, replace the control valves.



Oxidation in the contacts of the electric cables of the wiring harness.

Clean the contacts.

Interruption of the electric cable.

Replace the electric cable.

Damage to the solenoids/solenoid valves.

Replace the solenoids.

Damage to sensors.

Replace sensors.

Short circuits or bad contact.

Check and, if necessary, replace the fuses.

EGM/ECU gearshift electronic control operation fault.

Replace the electronic control of the EGM/ECU gearshift.



Check for possible oil leaks.

Eliminate the leaks and restore the oil level.

Suction strainer restriction.

Clean the suction strainer.

Damaged oil pump.


Damaged oil pump pressure relief valve.


Damaged/restricted filter.

Replace the filter.

Damaged / stuck control valve.


Damaged converter.


Oil temperature below 0 °C (32 °F).


Damaged rotary seal rings.

Replace the rotary seal rings.


Repair the shuttle lever.

Excessively worn-out clutch assembly. Repair and, if necessary, replace the clutch discs. Lack of motion transmission (broken gears, shafts, bearings, etc.).


Copyright © 332


FAULT

POSSIBLE CAUSE The brake does not release.

ACTION Check the general pressure of transmission. Check voltage. Check the operation of the solenoid valve. Check the mounting of the brake solenoid valve block after operating on the brake. After the above-described verifications, disassemble the brake cover and check the condition of the parts for unlocking/locking the brake (seal rings, belleville washers, brake disc deformation, etc.).

The vehicle has a reduced power transmission.

Overheating.

Incorrect oil temperature.


Transmission oil overheating.

Restore acceptable temperature values.

Incorrect operating pressures.

Check the hydraulic circuit and replace (oil pump, filters, control valve).

Damaged converter.




Worn-out clutch assembly.

Replace/repair.

4WD fails to engage.

Repair/replace the 4WD shaft assy.

Overheated solenoids/solenoid valves.

Replace.



Software of EGM/ECU gearshift electronic control faulty.

Replace EGM/ECU.

Damage to sensors.

Replace sensors.

Damaged cooling system.

Repair the cooling system.

Dirty heat exchanger.

Clean the heat exchanger.

Unintentionally activated parking brake.

Deactivate the parking brake.

Excessive soil deposit on axle wheel hubs.

Clean the axle wheel hubs.


FAULT

Wheel rotation with lifted vehicle.

Noise.

Irregular coupling.

POSSIBLE CAUSE

333

ACTION



Braking force external to transmission: axle operating problem.

Check and repair the axle.



Damaged converter.


Damaged oil thermostat.

Replace the oil thermostat.



Worn-out oil pump.






Incorrect oil gradient.

Change oil and filters.





Damaged converter.


Damaged oil pump.


Ventilation/Cavitation.

Check the oil level. Check the oil gradient.





Damaged hydraulic control valve.

Replace the control valves.





Damaged converter.




Overheating.

See “overheating”.


Replace EGM/ECU.



Copyright © 334


FAULT

POSSIBLE CAUSE

The gear remains engaged.

Damaged/stuck shuttle lever.








Damaged clutch assembly.

Repair and, if necessary, replace the clutch assembly.


Replace EGM/ECU.

Damaged 4WD connection assy.


Hydraulic system fault.




Braking sensor fault.

Check and, if necessary, replace the braking sensors.




Replace EGM/ECU.

Damaged clutch engagement assy.

Replace the clutch engagement assy.





Damaged pressure sensors.

Check and, if necessary, replace the sensors.




Replace EGM/ECU.

Lack of 4WD power transmission.

Gear fails to engage.

ACTION


335

REPAIR TIMES The times are referred to average values of maintenance performed by skilled personnel in workshops equipped with all necessary fixtures for a proper execution of the required works. The repair and/or replacement times are indicated in minutes. We assume that the transmission assy has already been removed from the machine. ASSY

Plugs and filters

OPERATION

TIME (minutes)

Oil filter replacement

5

Oil temperature sensor replacement

5

Revolutions sensor replacement

5

Converter replacement

10

Oil pump replacement

20

Replacement of lubrication and gearshift lines (each)

5

Control valve replacement

20

Control valve overhauling

40

Solenoid valve replacement (each)

5

PTO shaft replacement

30

Replacement of seal rings on input shaft

20

Half box replacement

80

Open, clean, close the half boxes

50

Replacement of shaft A / bearings

60

Overhauling of shaft A

150

Replacement of seal rings on shaft A

120

Replacement of shaft D / bearings

60

Overhauling/replacement of shaft B

150

Replacement of bearings of shaft B

60

Overhauling/replacement of shaft B

180

Replacement of bearings of shaft C

60

Overhauling/replacement of shaft E

100

Replacement of bearings of shaft E

60

Replacement of seal rings on shaft E

70

Solenoid valve replacement

10

Disc kit replacement

40

Replacement of seal rings on piston

20

Oil pump Lines

Control valve

Transmission box

Shafts A and D

Shafts B

Shafts C

Shaft E

Parking brake

Copyright © 336



DESCRIPTION

USE

380002211

Handle


380200190

Buffer

Assembly / disassembly of several bearings

380200197

Buffer

Assembly of shaft A bearings

380200203

Buffer

Assembly of several bearings and of 2nd travel gear

380200214

Calibrator


380200215

Attachment

Disassembly / assembly of clutch

380200218

Buffer

Assembly of oil pump seal ring

380200223

Check

Piston check

380200224

Cover and shims

Several seal ring assembly

380200225

Plunger

Several seal ring assembly

380001926

Protection

Clutch piston assembly

380200226

Buffer

Assembly of SAHR seal ring for parking brake

380200230

Buffer

Assembly of bearings of shaft D

380200240

Cover and shims

Seal ring assembly

380001933

Cover and shims


380001927

Calibrator


380001928

Plunger


380200241

Calibrator

Assembly of seal ring on shaft

380200239

Hook

Lifting of shafts B, C, E and of gear control yokes

380200257

Protection

Assembly of seal ring on PTO shaft

380200242

Plunger

Seal ring assembly

380200248

Protection

Assembly of seal ring on shaft C

380200250

Calibrator


380200251

Cover and shims


380200252

Plunger


380200253

Calibrator


380200256

Sleeve

Shaft disassembly

380200275

Tool

Assembly of snap ring on shaft E

380200258

Puller

Disassembly of snap ring on shaft E

380200220

Drift

Assembly of bearings of shaft E

380200229

Drift

Assembly of bearings of shaft E

2WS 4WS

Copyright ©

580T 580ST 590ST 695ST

SECTION 25 - FRONT AXLE 2WD - 2WS FRONT AXLE ............................................................................................................................... 3 TECHNICAL SPECIFICATIONS.................................................................................................................. 3 LUBRICATION AND GREASING ................................................................................................................ 4 REMOVAL FROM MACHINE ...................................................................................................................... 6 DISASSEMBLY AND ASSEMBLY............................................................................................................... 7 TROUBLESHOOTING................................................................................................................................. 7 4WD - 2WS FRONT AXLE ............................................................................................................................. 10 TECHNICAL SPECIFICATIONS................................................................................................................ 10 LUBRICATION AND GREASING .............................................................................................................. 11 REMOVAL FROM MACHINE .................................................................................................................... 13 DISASSEMBLY AND ASSEMBLY............................................................................................................. 14 TROUBLESHOOTING............................................................................................................................... 57 SPECIAL TOOLS....................................................................................................................................... 61 4WS FRONT AXLE......................................................................................................................................... 62 TECHNICAL SPECIFICATIONS................................................................................................................ 62 LUBRICATION AND GREASING .............................................................................................................. 63 REMOVAL FROM MACHINE .................................................................................................................... 65

Copyright © 2

SECTION 25 - FRONT AXLE

Copyright © SECTION 25 - FRONT AXLE

3

2WD - 2WS FRONT AXLE TECHNICAL SPECIFICATIONS

Manufacturer Model

CNH Steering

Copyright © 4


LUBRICATION AND GREASING Oil capacity Oil type

1. Level and fill plug for differential oil 2. Air breather 3. Level, fill and drain plug for reduction gear oil 4. Oil drain plug 5. Greasing points

0.2 litres (0.044 gal) Akcela Transaxle fluid 80W -140

Copyright © SECTION 25 - FRONT AXLE Before draining the oil from the axle body, use the breather (2) to release any possible internal pressure.

WARNING Risk of violent oil ejection.

To drain the oil from the central body remove the level plug (1) and the drain plug (4).

WARNING Risk of violent oil ejection. Drain all oil. Clean, screw in and tighten the drain plug (4). Fill through the hole of the plug (1). Check the level and, if necessary, top up. Clean, screw and tighten the plug (1). Before draining the oil from the reduction gear, rotate it so that the plug (3) is in the highest position (position A) and partially unscrew the plug to release any possible internal pressure. Turn and bring the plug to the lowest position (position B). Remove the plug and drain the oil. Now turn again and bring the hole of the plug (3) to check and oil filling position (position C). Carry out the filling. Clean, screw and tighten the plug (3).

5

Copyright © 6


REMOVAL FROM MACHINE Move the machine to a level and firm ground, away from any soft ground, excavations and poorly shored cavity. Rest the loader attachment on the ground in order to unload the weight of the machine from the 2 front wheels, then lift the front part, thus ensuring the safety of the subsequent operations. Use the locking pin (if provided) to lock the loader attachment controls. Place the backhoe attachment in the road travel position. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Completely raise the stabilizers and lock them mechanically. Stop the engine and remove the starter key. Release the hydraulic pressure by operating the control levers in all directions. On hydraulically controlled machines, turn the key to ON and release the pressure by moving the hydraulic control levers in all directions. Place some wedges under the wheels so as to prevent the machine from moving. Disconnect the electric system by disconnecting the battery master switch. Fasten the front axle (3) to a lifting hoist or to a support. Now it is possible to carry out the disassembly of the 2 front tyres by loosening and removing the relevant fixing nuts (7) [tightening torque = 330 Nm (243 lbf·ft)]. Disconnect the hoses of the steering cylinder, paying attention to possible oil leaks, preventing spillage over the ground using a container. Remove the snap ring (6) from the machine side, and keep the shims (4). Using a soft hammer, tap the pin (5) in order to extract it from the relevant hole, on the front side of the machine. Once the pin (5) has been disassembled, it is possible to remove the front axle (3).


7

DISASSEMBLY AND ASSEMBLY (See 4WD front axle)

TROUBLESHOOTING FAULT Bent axle beam body.

POSSIBLE CAUSE

ACTION

Overloaded vehicle.

Replace the axle beam body.

Damaged vehicle.


Insufficient lubrication.

Replace the bearings and top up oil.

Contaminated oil.

Change the oil, fill up to right level and replace at recommended intervals.

Excessive use.

Replace the bearings.

Normal wear.


Prolonged operation with oil at a high temperature.

Replace the gasket or seal and matching surface if damaged.

Incorrectly installed seal.

Correctly lubricate and change oil and seals at recommended intervals.

Damaged seal lip.

Replace the seal.

Contaminated oil.


Bent or broken axle beam.

Intensive use of the vehicle or overloaded vehicle.

Replace the axle beam.

Axle shaft broken on wheel side.

Loose wheel support.

Replace the axle beam and check if the wheel support is worn out or wrongly adjusted.

Bent axle beam body.


Incorrect installation.

Correct the installation.

Faulty differential.

Inspect and repair the axle.

Wrong weight distribution.

Distribute the weight differently.

Overload.

Remove the excessive load.

Incorrect tyre rotation radius.

Replace the tyre or adjust pressure on both tyres.

Bent or broken axle shaft.


Worn out or pitted bearings.

Oil leakage form the seals.

Wheel vibration and tyre resistance.

Copyright © 8


FAULT Difficult steering; the machine travels in a straight line while steering.

Excessive noise.

Uneven wear of tyre.

Friction noise.

POSSIBLE CAUSE

ACTION




Replace the differential.



Overload.












Overload.






Incorrect wheel alignment.

Replace the parts and check that the bearings are in good conditions.

Incorrect axle part installation.

Check the installation.





Overload.








Incorrect wheel adjustment.

Carry out the adjustment and check that the bearings are in good conditions.





Damaged or worn axle parts.


Presence of foreign objects.

Discard.




FAULT Vibrations during travel.

Intermittent noise.

POSSIBLE CAUSE

9

ACTION





Overload.








Damaged ring gear.

Replace bevel gear.

Differential box screws loose.

Tighten the screws to torque.





Overload.








Copyright © 10


4WD - 2WS FRONT AXLE TECHNICAL SPECIFICATIONS

Manufacturer Model

CNH Steering

Steering angle

According to the type

Total reduction ratio

According to the type

Lubrication angle

35° maximum (front and rear) - 35° maximum (from side to side)


11

LUBRICATION AND GREASING

Oil capacity Oil type

1. Level and fill plug for differential oil 2. Air breather 3. Level, fill and drain plug for reduction gear oil 4. Oil drain plug 5. Greasing points

Differential

6.5 litres (1.43 gal)

Final drive (each)


Akcela Transaxle fluid 80W -140

Copyright © 12


Before draining the oil from the axle body, use the breather (2) to release any possible internal pressure.




Copyright © SECTION 25 - FRONT AXLE REMOVAL FROM MACHINE Move the machine to a level and firm ground, away from any soft ground, excavations and poorly shored cavity. Rest the loader attachment on the ground in order to unload the weight of the machine from the 2 front wheels, then lift the front part, thus ensuring the safety of the subsequent operations. Use the locking pin (if provided) to lock the loader attachment controls. Place the backhoe attachment in the road travel position. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Completely raise the stabilizers and lock them mechanically. Stop the engine and remove the starter key. Release the hydraulic pressure by operating the control levers in all directions. On hydraulically controlled machines, turn the key to ON and release the pressure by moving the hydraulic control levers in all directions. Place some wedges under the wheels so as to prevent the machine from moving. Disconnect the electric system by disconnecting the battery master switch. Fasten the front axle (4) to a lifting hoist or to a support. Now it is possible to carry out the disassembly of the 2 front tyres by loosening and removing the relevant fixing nuts (5) [tightening torque = 330 Nm (243 lbf·ft)]. Disconnect the hoses of the steering cylinder, paying attention to possible oil leaks, preventing spillage over the ground using a container. Disconnect the cardan joint (1). Loosen and remove the screws (2) with the relevant washers (3) [tightening torque = 460 ÷ 540 Nm (339 ÷ 398 lbf·ft)]. Remove the front axle (4).

13

Copyright © 14


DISASSEMBLY AND ASSEMBLY NOTE: The 2WD and 4WD axles are identical, with the following exceptions: the 2WD axle has pressed steel plugs in the bores, while the 4WD has internal gears and shafts. The 2WD axle reduction gear has no planetary carrier. MOUNTING SCREW TORQUE

Tie rod nut, standard Tie rod nut, HD

111 ÷ 137 Nm (82 ÷ 101 lbf·ft) 213 ÷ 263 Nm (157 ÷ 194 lbf·ft)

Tie rod ball joint nut, standard

129 ÷ 160 Nm (95 ÷ 118 lbf·ft)

Ball joint nut, HD

162 ÷ 200 Nm (119 ÷ 147 lbf·ft)

Tie rod ball joint nut, standard

255 ÷ 315 Nm (188 ÷ 232 lbf·ft)

Breather

11 ÷ 14 Nm (8 ÷ 10 lbf·ft)

Oil drain plug

54 ÷ 66 Nm (40 ÷ 49 lbf·ft)

Lubrication fitting, king pin

20 ÷ 30 Nm (15 ÷ 22 lbf·ft)

Planet carrier retention screw King pin screw

21 ÷ 26 Nm (15.5 ÷ 19 lbf·ft) 154 ÷ 188 Nm (114 ÷ 139 lbf·ft)

Differential cover screw

96 ÷ 118 Nm (71 ÷ 87 lbf·ft)

Steering cylinder screw

358 ÷ 442 Nm (264 ÷ 326 lbf·ft)

Steering stop nut

200 ÷ 244 Nm (148 ÷ 178 lbf·ft)

Shaft retaining nut

358 ÷ 442 Nm (264 ÷ 326 lbf·ft)

Ring gear support screw, standard

88 ÷ 108 Nm (65 ÷ 80 lbf·ft)

Ring gear support screw, HD

96 ÷ 118 Nm (71 ÷ 87 lbf·ft)

Gear pin screw

95 ÷ 105 Nm (70 ÷ 77 lbf·ft)

Oil drain plug

72 ÷ 88 Nm (53 ÷ 65 lbf·ft)

Bearing cup screw

96 ÷ 118 Nm (71 ÷ 87 lbf·ft)

Ring nut retainer screw

21 ÷ 26 Nm (15.5 ÷ 19 lbf·ft)

Ring gear screw

96 ÷ 118 Nm (71 ÷ 87 lbf·ft)

Pinion

1.7 ÷ 2.2 Nm (1.2 ÷ 1.6 lbf·ft)

Differential

1.5 ÷ 2.5 Nm (1.1 ÷ 1.8 lbf·ft)

Wheel bearing with seal, standard

8 ÷ 25 Nm (6 ÷ 18 lbf·ft)

Wheel bearing with seal, HD

12 ÷ 25 Nm (9 ÷ 18 lbf·ft)

Standard differential

0 ÷ 1 Nm (0 ÷ 0.7 lbf·ft)

Limited slip differential

1 ÷ 5 Nm (0.7 ÷ 4 lbf·ft)

Copyright © SECTION 25 - FRONT AXLE WHEEL HUB

Disassembly Unscrew and remove the plug (1) and drain the oil.

15

Copyright © 16



Separate the planetary carrier (3) from the axle using the two slots for prying.

Remove the planetary gear carrier assy (3).


Copyright © SECTION 25 - FRONT AXLE Mark the washers and grease the pins.

Remove the washers (18).

Inspect the washers (18) for dents or damage in roller contact area.

If necessary, remove the gears.

17

Copyright © 18


Wipe off any contamination on the drain plug.

Loosen the caulking on the nut (5).

Unscrew the ring nut (5) by means of tool 380000468.

Remove the ring nut (5).

Copyright © SECTION 25 - FRONT AXLE Loosen and remove the screws (10).

Tighten the 2 screws (10) in the 2 threaded holes in the hub. Tighten the 2 screws evenly until the ring gear carrier (11) is free of the swivel housing.

Remove the ring gear (6).

Remove the wheel hub (13) complete with swivel housing using a puller.

19

Copyright © 20


Remove the outer bearing (15).

Separate the wheel hub (13) from the swivel housing.


Remove the inner bearing (16).

Copyright © SECTION 25 - FRONT AXLE Remove the snap ring (12) which fastens the ring gear (6) in the ring gear carrier (11).

Separate the ring gear carrier (11) and the ring gear (6).

If necessary, remove the bushings (14).

Remove the bearing cups (15) and (16), if necessary.

21

Copyright © 22


Checks Clean all parts in cleaning solvent. Inspect the bearing cup and the rollers in the bearings for flat areas, pitting, scoring, and other damage. Also check the inner race for damage. If any of these defects are found, new bearings and new bearing cups must be installed. Inspect the pins for wear and damage. Inspect the teeth of the gears and of the ring gear for wear, pitting, scoring or other damage. Use new parts as required.

Assembly If bearing cups were removed, use an acceptable driver to press new bearing cups into the wheel hub.

The word “OUTSIDE” on the seal ring (17) must be facing up. Use tool DMT100004 to insert the new seal ring into the wheel hub. Do not damage the seal ring.

Copyright © SECTION 25 - FRONT AXLE Insert the new rollers using tool DMT100002.

Apply grease to help retain the rollers.

Make sure that all required rollers have been installed.

Install the gears (8) onto the pins, respecting the reference marks traced during disassembly.

23

Copyright © 24


Remove tool DMT100002.

Check the correct assembly of all rollers.

Install the washers (18). Where possible, match the washers with the relevant pins, respecting the reference marks traced during disassembly.

Screw in and tighten the screws (9).

Copyright © SECTION 25 - FRONT AXLE Press the bushings (14) into the ring gear carrier (11).

Assemble the ring gear carrier (11) and the ring gear (6).


Assemble the cup of the inner bearing into the swivel housing. Installation will be easier if you heat the bearing slightly. Do not heat the bearing more than 149 °C (300 °F). Assemble the wheel hub (13).

25

Copyright © 26


Install the outer bearing (15). Installation will be easier if you heat the bearing slightly. Do not heat the wheel bearing more than 149 °C (300 °F).

Align the holes in the ring gear carrier (11) with the holes in the swivel housing and install the ring gear carrier.

Install and tighten the screws (10) evenly to pull the hub against the swivel housing. Tighten the screws (10) to a tightening torque of 358 ÷ 442 Nm (264 ÷ 326 lbf·ft).

Tighten the ring nut (5) using tool 380000468, to a tightening torque of 358 ÷ 442 Nm (264 ÷ 326 lbf·ft).

Copyright © SECTION 25 - FRONT AXLE Assemble a new O-ring (4).

Assemble the planetary carrier (3).

Screw in and tighten the 2 screws (2) to a tightening torque of 21 ÷ 26 Nm (15.5 ÷ 19 lbf·ft). Screw on the plug (1) after oil filling.

27

Copyright © 28


SWIVEL HOUSING

Disassembly Unscrew and remove the tie rod nut (1).

Copyright © SECTION 25 - FRONT AXLE Use a two-jaw puller to loosen the ball joint.

Remove the ball joint (2).


Remove the steering cylinder (3).

29

Copyright © 30


Fasten the swivel housing (10) to an appropriate lifting tool. Loosen the screws (6).

Remove the screws (6) and the top king pin (7).

Repeat the same operations to remove the bottom king pin.

Remove the swivel housing (10) together with the cardan joint (14).

Remove the belleville washer (9) from the top and bottom of the axle body.

Copyright © SECTION 25 - FRONT AXLE Remove the bearing (8) from the top and bottom of the axle body by means of a puller.

Remove the seal (15) by means of a puller.

Remove the bushing (16) by means of a puller.

Remove the bearing cup (8) from the king pin (7) using a hammer and a chisel.

31

Copyright © 32


Assembly Install the bushing DMT100005.

(16)

by

means

of

tool

Install the seal (15) by means of tool DMT100006.

Assemble the bearing (8).

Assemble the swivel housing (10) together with the cardan joint (14).

Assemble the belleville washers (9). Fasten the swivel housing (10).

Copyright © SECTION 25 - FRONT AXLE Assemble the top king pin (7). Tighten the screws (6) to a tightening torque of 154 ÷ 188 Nm (114 ÷ 139 lbf·ft).

Assemble the bottom king pin (7). Tighten the screws (6) to a tightening torque of 154 ÷ 188 Nm (114 ÷ 139 lbf·ft).

Assemble the ball joint (2) and the nut (1).

Tighten the nut (1) for 2WD to 129 ÷ 160 Nm (95 ÷ 118 lbf·ft). Tighten the nut (1) for 4WD to 162 ÷ 200 Nm (119 ÷ 147 lbf·ft).

33

Copyright © 34 CARDAN JOINT

Disassembly Remove the 4 snap rings (3).


Copyright © SECTION 25 - FRONT AXLE Use the CAS1980 V-block to support the coupling (5). Adjust the screws in the V-block to hold the coupling level. Use a driver and press the bottom bearing cup against the V-block.

Fasten the bearing cup in a vice and drive the coupling off the bearing cup.

Use the V-block to support the coupling and press the other bearing cup against the V-block.

Remove the long axle shaft (2) from the coupling (5).

35

Copyright © 36


Remove the coupling (5) from the bearing cup.

Press the bottom bearing cup out of the yoke.

Remove the yoke from the bearing cup. DO NOT hit the axle shaft in the seal area.

Press the other bearing cup out of the yoke.

Copyright © SECTION 25 - FRONT AXLE Remove the cross (4).

Press the bearing cup out of the yoke.

Press the bearing cup into the yoke until the top of the bearing cup is 6 mm (0.24 in) above the top of the yoke.

Carefully install the cross (4) in the bearing cup.

37

Copyright © 38


Press the other bearing cup into the yoke until the top of the bearing cup is 9 mm (0.35 in) above the top of the yoke.

Carefully remove the cross (4) from the bearing cup so that the cross is in both bearing cups.

Hold the cross and press the bearing cups into the yoke.

Press a bearing cup into the yoke so that a snap ring can be installed.

Copyright © SECTION 25 - FRONT AXLE Assemble the snap ring (3).

Repeat the same operations for the other bearing cup. Use the V-block to support the coupling and press the bearing cup into the coupling evenly with the outer diameter of the coupling.

Carefully install the cross (4) into the bearing cup.

Press the other bearing cup into the coupling until the bearing cup is 6 mm (0.24 in) above the top of the yoke.

39

Copyright © 40


Carefully raise the cross into the top bearing cup so that the cross is in both bearing cups.

Hold the cross and press the bearing cup into the coupling so that a snap ring can be installed.


Repeat the same operations for the other bearing cup.

Copyright © SECTION 25 - FRONT AXLE DIFFERENTIAL

Disassembly Loosen and remove the differential carrier screws (1).

41

Copyright © 42


Remove the differential carrier (2) by means of a suitable lifting device.

Place the differential on an approved working area.

Prevent the pinion from turning. Measure the backlash of the ring gear. Record the reading.

Make an identification mark on the supports and ring nut on one side of the differential carrier.

Copyright © SECTION 25 - FRONT AXLE Loosen and remove the screws (29) and the washers (28).

Loosen both adjusting ring nuts (15) by means of tool DMT100002.

Remove the screws (26) and the supports (27).

Remove the differential assy.

43

Copyright © 44


Remove the seal (4) and the cover (3).

Loosen and remove the nut (5) of the pinion using tool 380000468 and tool 380100102.


Extract the pinion (13) using a press.

Copyright © SECTION 25 - FRONT AXLE Remove the washers (8) and (10) and the spacer (9).

Separate the pinion (13) from the inner bearing (11).

Remove the shim (12).

Use a soft punch to remove the bearing cups only if the inspection indicates the need for new parts.

45

Copyright © 46


Remove the seal (30) from the cover (3).

Remove the O-ring (4) from the cover (3).


Remove the ring gear (17).

Copyright © SECTION 25 - FRONT AXLE Remove the gear (18).

Remove the retaining pin (19).

Remove the pin (20) and the gears (22).

47

Copyright © 48


Remove the thrust washer (24) and the gear (23).

Checks Clean all parts in cleaning solvent. Inspect the bearing cups and the bearings for flat areas, pitting, scoring and other damage. Also check the inner race for damage. If any of these defects are found, new bearings and bearing cups must be installed. Inspect the teeth on the pinion and of the ring gear for pitting, scoring and broken teeth. The ring gear and pinion gear must be replaced as a set. Inspect the gears, the pins and the teeth of the pinion gears for pitting, scoring and other damage. Also inspect the thrust surfaces and the bores of each gear. Check the splines in the gears for wear. Inspect the thrust washers for pitting, scoring and other damage.

Copyright © SECTION 25 - FRONT AXLE Assembly Assemble the thrust washer (24) and the gear (23).

Install the pin (20) and the gears (22).

Install the retaining pin (19).

NOTE: before assembly, grease all gear contact surfaces.

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Copyright © 50



Make sure that the mounting surfaces of the ring gear (17) are clean and install the ring gear. Screw in and tighten the screws (14) to a tightening torque of 96 ÷ 118 Nm (71 ÷ 87 lbf·ft).

Assemble the bearing cup(s) into the differential carrier. Use a feeler to ensure cups are fully seated.

Install the shim (12). The chamfer of the shim must be towards the pinion.

Copyright © SECTION 25 - FRONT AXLE Press the bearing (11) against the shim. Use a feeler gauge to ensure bearing is fully seated.

Lubricate the bearing (11).

Install a new spacer (9) and the washers (8) and (10).

Insert the pinion (13). Install the bearing (7).

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Copyright © 52


Assemble the washer (6).

Install a new nut (5). Use a yoke and the wrench 380000468 to tighten the nut.

The pinion and bearings will still be loose. Progressively tighten the nut until the bearings become seated. NOTE: If the nut is tightened too much (rotating torque higher than specified), the pinion must be removed and a new spacer must be installed on the pinion. Use tool 380100102 and a torque wrench to check the rotating torque of the pinion. It must be rotated while tightening the nut. Final reading to be verified after 3 complete revolutions. The rotating torque must be 1.7 ÷ 2.2 Nm (1.2 ÷ 1.6 lbf·ft). If the rotating torque is lower than specified, further tighten the nut and check the rotating torque again.

Copyright © SECTION 25 - FRONT AXLE When the rotating torque is as specified, use a hammer and punch and partially drive the nut (5) into the slot in the pinion.

Assemble a new O-ring (4) on the cover (3).

Assemble a new seal (30) in the cover (3) using tool DMT100001. The seal will be approximately 1/16 from the inner face of the cover.

Lubricate the O-ring and the seal. Assemble the cover (3).

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Copyright © 54


Install the differential carrier assy and lubricate the bearings.

Assemble the supports (27) with the alignment marks. Tighten the screws (26) to 20 Nm (15 lbf·ft) to pull the supports against the differential carrier (do not overtighten). The bearings must be able to rotate.

Assemble the adjusting ring nuts (15). Tighten both adjusting ring nuts (15), making sure there is some backlash between the ring gear and the pinion.

Rotate the pinion by approx. 3 or 4 turns and ensure proper seating. Check in 3 places, approximately 120° apart. The value of the rolling torque must be 0.0009 ÷ 0.0015 Nm (0.0006 ÷ 0.0011 lbf·ft). If values vary more than 0.001 Nm (0.0007 lbf·ft), then replace bevel set. If backlash value is too large, loosen the ring nut by one slot on gear side and tighten the ring nut slot on the back face of the ring gear. If backlash value is too small, do the opposite of the above-described operations.

Copyright © SECTION 25 - FRONT AXLE Make the final adjustments of the ring nuts to align locking devices and confirm the rolling torque. Apply the yellow compound on the bevel set in 3 places, 120° apart, on 3 teeth each. Rotate bevel set enough to see pattern in yellow compound. Pattern should be per chart above. Normal wear will flatten (elongate) the contact pattern. NOTE: this is a non-adjustable bevel set. If pattern is significantly different from specifications, then replace bevel set. If the original ring gear and pinion gear are being used, the backlash must be equal to the measurement made during disassembly. Tighten the screws (26) to the prescribed torque of 266 Nm (196 lbf·ft). Screw in the lock screw (29) which blocks the ring gear and tighten to a tightening torque of 162 ÷ 200 Nm (119 ÷ 147 lbf·ft).

Apply some sealant.

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Copyright © 56


Assemble the differential carrier (2).

Screw in and tighten the screws (1) to a tightening torque of 162 ÷ 200 Nm (119 ÷ 147 lbf·ft).


57

TROUBLESHOOTING FAULT Ring gear tooth broken on the outer side.

Ring gear tooth side broken.

POSSIBLE CAUSE Excessive gear load compared to the one expected.

Replace bevel gear set.

Incorrect ring gear adjustment (excessive backlash).

Follow carefully the recommended operations for the adjustment of the bevel gear set backlash.

Loose pinion nut.

Tighten the pinion nut.

Load bump.


Incorrect ring gear adjustment (insufficient backlash).

Follow carefully the recommended operations for the adjustment of the bevel gear set backlash.

Loose pinion nut.

Tighten the pinion nut.

Worn pinion or ring gear teeth. Insufficient lubrication. Contaminated oil. Incorrect lubrication or depleted additives.

Overheated ring gear and pinion teeth. Check if ring gear teeth are damaged.

ACTION

Replace bevel gear set. Follow carefully the recommended operations for the adjustment of the bevel gear set backlash.

Worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring gear.

Use proper lubricants, fill up to the right levels and replace at recommended intervals.

Prolonged operation at high temperatures.


Inappropriate lubricant.

Use proper lubricants, fill up to the right level and replace at recommended intervals.

Low oil level. Contaminated oil. Pinion teeth pitting.


Worn out or pitted bearings.

Excessive use.



Use correct lubrication, fill up to the right level and substitute at recommended intervals.

Overloaded vehicle.


Damaged vehicle.



Replace the bearings and top up oil.

Contaminated oil.


Excessive use.


Normal wear.


Copyright © 58


FAULT Oil leakage form the seals.

POSSIBLE CAUSE

ACTION

Prolonged operation with oil at a high temperature.

Replace the gasket or seal and matching surface if damaged.

Incorrectly installed seal.

Correctly lubricate and change oil and seals at recommended intervals.

Damaged seal lip.

Replace the seal.

Contaminated oil.


Use until worn.

Replace the flange.

Loose pinion nut.

Check that the pinion spline is not excessively worn out.

Pinion axle backlash.

Replace bevel gear set if required.

Fatigue failure of pinion teeth. See if the fracture line is well defined (wave lines, straight lines).

Use until worn.


Pinion and ring gear teeth breakage.

Crash load of differential components.

Check and/or replace other differential components.

Worn out side gear spline. Replace all scratched washers (excessive backlash).

Excessive use.

Replace differential gear group.

Worn out or scored thrust washer surface.

Excessive use.

Use correct lubrication and fill up to right level.

Inappropriate lubricant.

Replace at intervals recommended.

Contaminated oil.

Replace all scratched washers and those with a thickness by 0.1 mm (0.004 in) lower than the new ones.

Excessive use.

Replace bearing.

Excessive pinion axial backlash.

Check pinion axial backlash.

Insufficient lubrication Contaminated oil.

Use proper lubrication, fill up to right level and replace at recommended intervals.

Excessive wear of input flange spline.

Worn out inner diameter of tapered roller bearing.

Continuous overload.

Replace the axle shaft if required.


FAULT

POSSIBLE CAUSE

59

ACTION

Bent or broken axle beam.

Intensive use of the vehicle or overloaded vehicle.


Axle shaft broken on wheel side.











Overload.












Overload.












Overload.










Wheel vibration and tyre resistance.

Difficult steering; the machine travels in a straight line while steering.

Excessive noise.

Copyright © 60


FAULT Uneven wear of tyre.

Friction noise.

Vibrations during travel.

Intermittent noise.

POSSIBLE CAUSE

ACTION





Overload.








Incorrect wheel adjustment.

Carry out the adjustment and check that the bearings are in good conditions.







Presence of foreign objects.

Discard.







Overload.








Damaged ring gear.

Replace bevel gear.







Overload.









61


DESCRIPTION

USE

CAS-1980

V-block

Support for cardan joint disassembly

380100103

Protection

Assembly of differential carrier seal ring

DMT100001

Protection

Pinion seal ring assembly

DMT100002

Tool

Assembly of bearings

DMT100004

Buffer

Wheel hub seal ring assembly

DMT100005

Buffer

Assembly of bushing into the axle body

DMT100006

Buffer

Assembly of seal ring in axle body

DMT100007

Tool

Assembly of pinion bearing

380000468

Wrench

Pinion nut tightening

380100102

Wrench

Pinion nut tightening

Copyright © 62


4WS FRONT AXLE TECHNICAL SPECIFICATIONS

Manufacturer

CARRARO

Model

26.32

Differential ratio

2.75

Planetary hub ratio

6.92


19.04

Lubrication angle

35° maximum (front and rear) - 35° maximum (from side to side)


63



1. Oil level plug 2. Air breather 3. Level, fill and drain plug for reduction gear oil 4. Oil drain plug 5. Greasing points

Differential


Final drive (each)



Copyright © 64






Copyright © SECTION 25 - FRONT AXLE REMOVAL FROM MACHINE Move the machine to a level and firm ground, away from any soft ground, excavations and poorly shored cavity. Rest the loader attachment on the ground in order to unload the weight of the machine from the 2 front wheels, then lift the front part, thus ensuring the safety of the subsequent operations. Use the locking pin (if provided) to lock the loader attachment controls. Place the backhoe attachment in the road travel position. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Completely raise the stabilizers and lock them mechanically. Stop the engine and remove the starter key. Release the hydraulic pressure by operating the control levers in all directions. On hydraulically controlled machines, turn the key to ON and release the pressure by moving the hydraulic control levers in all directions. Place some wedges under the wheels so as to prevent the machine from moving. Disconnect the electric system by disconnecting the battery master switch. Fasten the front axle (6) to a lifting hoist or to a support. Now it is possible to carry out the disassembly of the 2 front tyres by loosening and removing the relevant fixing nuts (7) [tightening torque = 700 Nm (516 lbf·ft)]. Disconnect the hoses of the steering cylinder, paying attention to possible oil leaks, preventing spillage over the ground using a container. Disconnect the cardan joint (1) by unlocking and removing the screws (2) and the bracket (3). Loosen and remove the screws (5) with the relevant washers (4). Remove the front axle (6).

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Copyright © 66

NOTES:


Copyright ©

580T 580ST 590ST 695ST

SECTION 27 - REAR AXLE 2WS REAR AXLE (580T - 580ST).................................................................................................................... 3 TECHNICAL SPECIFICATIONS.................................................................................................................. 3 LUBRICATION AND GREASING ................................................................................................................ 5 REMOVAL FROM MACHINE ...................................................................................................................... 7 DISASSEMBLY AND ASSEMBLY............................................................................................................... 8 TROUBLESHOOTING............................................................................................................................... 61 REPAIR TIMES.......................................................................................................................................... 67 SPECIAL TOOLS....................................................................................................................................... 68 2WS REAR AXLE (590ST) ............................................................................................................................. 69 TECHNICAL SPECIFICATIONS................................................................................................................ 69 LUBRICATION AND GREASING .............................................................................................................. 71 REMOVAL FROM MACHINE .................................................................................................................... 73 DISASSEMBLY AND ASSEMBLY............................................................................................................. 74 TROUBLESHOOTING............................................................................................................................. 127 REPAIR TIMES........................................................................................................................................ 133 SPECIAL TOOLS..................................................................................................................................... 134 4WS REAR AXLE (695ST) ........................................................................................................................... 135 TECHNICAL SPECIFICATIONS.............................................................................................................. 135 LUBRICATION AND GREASING ............................................................................................................ 138 REMOVAL FROM MACHINE .................................................................................................................. 140 DISASSEMBLY AND ASSEMBLY........................................................................................................... 141 TROUBLESHOOTING............................................................................................................................. 219 REPAIR TIMES........................................................................................................................................ 225 SPECIAL TOOLS..................................................................................................................................... 227

Copyright © 2

SECTION 27 - REAR AXLE

Copyright © SECTION 27 - REAR AXLE

2WS REAR AXLE (580T - 580ST) TECHNICAL SPECIFICATIONS

3

Copyright © 4


Manufacturer

CARRARO

Model

28.44

Bevel gear reduction ratio

2.75/1

Epicyclic gear ratio

6.40/1


17.6/1

Input rotation Dry weight Differential type Pressure for differential lock Bevel gear set backlash

clockwise 420 kg (926 lb) Mechanical and driven 12 ÷ 35 bar (174 ÷ 508 psi) 0.20 ÷ 0.28 mm (0.0079 ÷ 0.0110 in)

Pinion bearing preload (1) (measured on Ø = 34.8 mm (1.37 in) without seal ring)

FP = 115 ÷ 138 N (26 ÷ 31 lbf)

Ring gear-pinion bearing total preload (1) (measured on Ø = 34.8 mm (1.37 in) without seal ring)

FT = (FP + 33) ÷ (FP + 50) N [FT = (FP + 7.4) ÷ (FP + 11.2) lbf]

Pinion bearing rolling torque (1) measured without seal ring Total pinion-ring gear bearing rolling torque (1) measured without seal ring

MP = 2.0 ÷ 2.4 Nm (1.47 ÷ 1.77 lbf·ft) MT = (MP + 0.58) ÷ (MP + 0.87) Nm [MT = (MP + 0.43) ÷ (MP + 0.64) lbf·ft]

(*) Only for new bearings

SERVICE BRAKE

Brake type

Wet disc brake

Brake operating temperature

-20 °C ÷ 150 °C (-4 ÷ 5.9 °F)

Maximum operating pressure

43 bar (624 psi)

Oil displacement for brake actuation (each side)

16 cm 3 (0.98 in3)

A. New counterdisc thickness = 8.0 ± 0.05 mm (0.31 ± 0.002 in) B. New friction disc thickness = 6.73 ± 0.1 mm (0.26 ± 0.004 in) Worn disc minimum thickness = 5.8 mm (0.23 in) C. New counterdisc thickness = 5.0 ± 0.05 mm (0.20 ± 0.002 in)


5

LUBRICATION AND GREASING Oil capacity (differential) Oil type

1. Level and fill plug for differential oil 2. Differential oil drain plug 3. Oil breather 4. Oil drain plug 5. Brake breather

17 litres (3.74 gal) Akcela Transaxle fluid 80W -140

Copyright © 6





WARNING Risk of violent oil ejection. Drain all oil. Clean the plug (2), screw it and tighten to the prescribed torque of 80 Nm (59 lbf·ft). Fill through the hole of the plug (1). Check the level and, if necessary, top up. Clean the plug (2), screw it and tighten to the prescribed torque of 80 Nm (59 lbf·ft).

Copyright © SECTION 27 - REAR AXLE REMOVAL FROM MACHINE Move the machine to a level and firm ground, away from any soft ground, excavations and poorly shored cavity. Lower the loader attachment to the ground. Use the locking pin (if provided) to lock the loader attachment controls. Lower the backhoe attachment to the ground. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Lower the stabilizers until the rear wheels are slightly lifted from the ground (they are free from machine weight). Stop the engine and remove the starter key. Release the hydraulic pressure by operating the control levers in all directions. On hydraulically controlled machines, turn the key to ON and release the pressure by moving the hydraulic control levers in all directions. Disconnect the electric system by disconnecting the battery master switch. Fasten the rear axle to a lifting hoist or to a support. Now it is possible to carry out the disassembly of the 2 rear tyres by loosening and removing the relevant fixing nuts (9) [tightening torque = 700 Nm (516 lbf·ft)]. Disconnect the cardan joint (6) by unlocking and removing the screws (7) and the bracket (8). Unscrew and remove the screws (4) with the nuts (2) and the washers (3) and (5) [tightening torque = 610 ÷ 678 Nm (445 ÷ 500 lbf·ft)]. Remove the rear axle (1).

7

Copyright © 8


DISASSEMBLY AND ASSEMBLY Some of the following pictures could not exactly show your axle, but the procedure is correct. TIGHTENING TORQUES AND APPLICATION OF SEALANTS / ADHESIVES A. Loctite 510 B. Loctite 270 C. Loctite 638

Copyright © SECTION 27 - REAR AXLE GREASE POINTS

9

Copyright © 10


FRONT FLANGE

Disassembly Remove the stop ring (1) and the front flange (2). Remove the O-ring (4) and the shim (5).


Copyright © SECTION 27 - REAR AXLE Assembly Assemble the seal ring (3) into the central body with a drift 380200228 and a hammer.

Insert the shim (5) and a new O-ring (4) into the pinion shaft. Insert the front flange (2) on the shaft end. Fasten the pieces as soon as assembled by fitting the snap ring (1).

11

Copyright © 12


BRAKES

Disassembly Drain the oil completely from the differential.

Loosen and remove all screws (1) except for 2 as a safety measure.

Copyright © SECTION 27 - REAR AXLE Connect the wheel hub (2) to a lifting device and tension the rope. Insert 2 opposed threaded rods to enable removal.

Remove the 2 last screws (1) and separate the wheel hub assy (2) from the axle body (3).

Slowly remove the wheel hub assy and the half axle (4), make sure that the braking discs (5) and the counterdiscs (6) stay on the wheel hub assy.

Place the wheel hub assy vertically and mark the counterdisc (5) assembled to the axle body side (3). Remove the discs (6), the counterdiscs (5) and the dowel pins (7).

13

Copyright © 14


Remove the half axle (4) from the wheel hub assy (2).

In some cases the axle shaft can be delivered already assembled in 2 parts.

Remove the screws (8) and the belleville washers (9) from the brake cylinder (10).

Check screws (8) and belleville washers (9) for damage. NOTE: if brake discs are replaced, also replace screws and springs.

Copyright © SECTION 27 - REAR AXLE Remove the snap ring (11) and the self adjust kit assy (12).

Place the self adjust kit (12) on tool 380200245 and remove the snap rings (13).

Check bushing (14) for wear. Repeat the procedure for the remaining 2 self adjust kits.

Remove the brake cylinder assy (10).

15

Copyright © 16


Remove the brake piston (15) from the brake cylinder (10).

Remove the O-rings (16) and (17) from the brake cylinder (10).

Remove the O-ring (18) from the brake piston (15).


Copyright © SECTION 27 - REAR AXLE Assembly Assemble the O-ring (19).

Assemble the O-ring (18) onto the brake piston (15).

Assemble the O-rings (16) and (17) onto the brake cylinder (10).

Lubricate the O-rings (16), (17) and (18). Assemble the brake piston (15) into the brake cylinder (10).

17

Copyright © 18


Lubricate the seat of the brake cylinder on the wheel hub (2) and assemble the dowel pins (7).

Assemble the brake cylinder assy (10) and remove the dowel pins (7).

Place the bushing (14) into tool 380200245 paying attention to direct it with the chamfer edge upwards.

Assemble the snap rings (13) by turning them by 90° with respect to the ring mounted before.

Copyright © SECTION 27 - REAR AXLE Assemble the snap rings (13) until they are seated against the calibrated disc and using a drift 380200245. Repeat the procedure for the remaining 2 self adjust kits.

Assemble the self adjust kits (12) into the brake cylinder, paying attention to direct the chamfer edge of the bushing (14) upwards.

Assemble the snap rings (11). Make sure that the teeth of the snap ring are directed towards the self adjust kit.

Snap ring (11) orientation.

19

Copyright © 20


Assemble the belleville washers (9) on the screws (8) paying attention to orient them correctly.

Assemble the screws (8) and the belleville washers (9). Tighten the screws (8) to a tightening torque of 15.3 Nm (11 lbf·ft). Make sure that the 4 belleville washers are correctly aligned before tightening the screws.

Assemble half shaft (4) and the dowel pins (7).

Using the reference mark made during disassembly, assemble the counterdisc (5) paying attention to direct it with the mark towards the axle body (3).

Copyright © SECTION 27 - REAR AXLE Assemble the first braking disc (6) and the counterdisc (5). If using new brake discs (6), they must be soaked in oil for at least 24 hours prior to installation.

Assemble the last brake disc (6) and make sure that its slots are aligned with those of the first disc.

Connect the wheel hub (2) to a lifting device and assemble it on the beam (3). Support and turn the axle beam (4), while pushing the wheel hub onto it.

Screw in screws (1) applying the prescribed sealant and tighten to tightening torque of 226 Nm (167 lbf·ft).

21

Copyright © 22


WHEEL HUB

Disassembly Remove the brake assy.

If disassembly of the planetary gear carrier for overhauling is not necessary, use a bearing puller to lift the planetary gear carrier assy.

Copyright © SECTION 27 - REAR AXLE Enlarge the snap ring (2) and simultaneously extract the gear carrier (1).

If necessary, remove the snap rings (3) and by means of a puller the gears (4) with the bearings (5) from the gear carrier (1). NOTE: the bearing (5) cannot be removed from the gear (4). If one gear must be replaced, replace the whole pair.

Unscrew and remove the ring nut (6) fastening the ring gear retaining hub using tool 380200244.

Separate the wheel hub (7) from the wheel flange (8) with a puller.

23

Copyright © 24


Connect the wheel hub (7) to a hoisting tool to remove it. Collect the bearing (9).

Remove the bearing cup (9) from the wheel hub (7).

Remove the seal ring (10) from the wheel hub (7).


Copyright © SECTION 27 - REAR AXLE Remove the spacer (12) from the wheel flange (8).

To remove the bearing (11), use a disc grinder to cut the cage and to engrave the ring. Then use a chisel to cut and to remove the ring.

Assembly Assemble the bearing cup (11) onto wheel hub (7) with the buffer 380200211. Assemble the bearing cup (9) with the buffer 380002222. Assemble the seal ring (10) on the wheel hub (7) with the buffer 380200254.

Use tool 380200254 (T) to assemble the seal ring (10) onto the wheel hub (7).

25

Copyright © 26


Assemble the bearing (11) onto wheel flange (8) with a pusher and a press.

Place the spacer (12) on the wheel flange (8).

Connect the wheel hub (7) to a lifting device and place it on the wheel flange (8). Clean the sealing surface of the flange. Pay attention not to damage the seal ring (10).

Assemble the bearing cup (9) with a pusher and a hammer. Assemble the ring nut (6).

Copyright © SECTION 27 - REAR AXLE Screw in and tighten the ring nut (6) with tool 380200244 at tightening torque of 1000 Nm (738 lbf·ft).

Assemble the bearing (5) with tool 380200255 (T).

Assemble the gears (4) and the snap rings (3) on the gear carrier (1). Ensure that the chamfer of the bearings (5) is directed towards the gear carrier (1).

Connect the gear carrier (1) to a hoisting tool to remove it. Lift it and then place it on the wheel hub (7).

27

Copyright © 28


Orient the gear carrier (1) so that the tooth engages into the ring nut (6).

In order to simplify the installation, align the hole on the gear carrier with the ring nut (6). NOTE: it may take several attempts to find the right combination of alignment between teeth and hole of the gear carrier and the ring nut, to get the locking tooth to engage.

Enlarge the snap ring (2) to complete the gear carrier (1) assembly.

Copyright © SECTION 27 - REAR AXLE DIFFERENTIAL SUPPORT ASSY



29

Copyright © 30


Separate the axle support (3) from the axle body (2) using pry bars in slots.

Connect the differential support (3) to a lifting device to remove it.

Measure the rolling torque MT0 of the bearings (pinion-ring gear system), using wrench 380200269. Note value MT0 that is necessary for assembling the bearings. NOTE: the total rolling torque must be determined without the pinion seal ring.

It is possible to measure the total starting preload FT0 of the bearings (pinion-ring gear system) using a dynamometer whose cord is wound on the end of the pinion shaft. Note value FT0 that is necessary for assembling the bearings.

Copyright © SECTION 27 - REAR AXLE Unscrew and remove the screws (4) fastening the ring nuts (5) and (6).

Unscrew the ring nuts (5) and (6) using tool 380200243.

Remove the differential box (7). The bearing cups (8) and (9) must be removed together with the differential box.

31

Copyright © 32


Assembly Assemble the bearing cups (8) and (9) on the differential box (7) with drift 380200218.

Assemble the differential box (7) with bearings onto the differential support (3).

Tighten both ring nuts (5) and (6) with special tool 380200243, till the backlash is eliminated and the bearings are slightly preloaded. Check that the bearings are correctly seated.

Position a magnetic-base dial gauge on the differential support, so that the feeler touches the surface of one tooth of the ring gear with a 90° angle.

Copyright © SECTION 27 - REAR AXLE Lock the pinion and alternately move the ring gear, and note the backlash between pinion and ring gear, measured with the dial gauge. Repeat the operation on two or more points (teeth), rotating the ring gear, so that to obtain an average value. Check if the measured backlash value is within the requested range: 0.20 ÷ 0.28 mm (0.0079 ÷ 0.0110 in) Carry out the adjustment by operating on the ring nuts (5) and (6) with tool 380200243. Adjust the ring nuts (5) and (6), remembering that: - if the measured backlash is less than the prescribed tolerance range, unscrew the ring nut (6) and screw in the ring nut (5) by the same measure; - if the measured backlash is more than the prescribed tolerance range, unscrew the ring nut (5) and screw in the ring nut (6) by the same measure.

Repeat the whole sequence of the above mentioned operations until the requested conditions are reached.

Once the pinion-ring gear backlash has been adjusted, if the bearings have not been replaced, measure the total preload FTm of the bearings (pinion-ring gear system), using a dynamometer whose cord is wound on the end of the pinion shaft. Use this method only if the bearings are already run in. The measured value FTm should be within the following range: FTm = FT0 ÷ (FT0 + 10) N FTm = FT0 ÷ (FT0 + 2.25) lbf

33

Copyright © 34


Once the pinion-ring gear backlash has been adjusted, if the bearings have not been replaced, measure the total rolling torque MTm of the bearings (pinion-ring gear system) with a torque meter and the special wrench 380200269. The measured value MTm should be the same of the starting: MTm = MT0

If the bearings have been replaced, measure the total preload FTm of the bearings (pinion-ring gear system), using a dynamometer whose cord is wound on tool 380200272 inserted on the pinion splined end.

The total preload FTm is measured by tool 380200237. The measured value should be within the following range: FTm = (FPm + 11) ÷ (FPm + 16.7) N [FTm = (FPm + 2.47) ÷ (FPm + 3.75) lbf] where FPm is the actual preload measured on tool 380200237 [gauge diameter Dm = 104.4 mm (4.11 in)].

NOTE: if you do not use the prescribed tool to measure the total preload FTm, the reference diameter is the diameter of pinion shaft splined end. The measured value should be within the following range: FTm = (FPm + 33) ÷ (FPm + 50) N [FTm = (FPm + 7.42) ÷ (FPm + 11.24) lbf] where FPm is the preload of the pinion bearings.

Copyright © SECTION 27 - REAR AXLE Once the pinion-ring gear backlash has been adjusted, if the bearings have been replaced, measure the total rolling torque MTm of the bearings (pinion-ring gear system) with a torque meter and the wrench 380200269.

WARNING All preloads must be measured without seal rings.

The total torque MTm should be within the following range: MTm = (MPm + 0.58) ÷ (MPm + 0.87) Nm [MTm = (MPm + 0.43) ÷ (MPm + 0.64) lbf·ft] where MPm is the preload of the pinion bearings.

If the measure is not within the requested range, check the assembly of each component and operate on the ring nuts (5) and (6) of the differential support: - if the total preload is less than the given range, screw on the ring nuts (5) and (6) by the same measure, keeping the pinion-ring gear backlash value unchanged; - if the total preload is less than the given range, screw on the ring nuts (5) and (6) with the same measure, keeping the pinion-ring gear backlash value unchanged. Once all the adjustment operations have been completed, lock the ring nuts (5) and (6) with the screws (4). Tighten the screws (4) to a tightening torque of 10 Nm (7.4 lbf·ft).

35

Copyright © 36


Before matching worked surfaces, make sure they are perfectly clean, if not, clean with proper detergents. Apply a film of sealant on the contact surface of the axle body (2) and the differential support.

Place the differential support (3) on the axle body (2).


Copyright © SECTION 27 - REAR AXLE Check of the bevel gear To test the marks of the bevel gear teeth, paint the ring gear with red lead paint. The contact mark test should always be carried out on the ring gear teeth and on both sides.

OK -> Correct contact: If the bevel gear is well adjusted, the mark on the teeth surfaces will be regular. Z -> Excessive contact on the tooth tip: approach the pinion to the ring bevel gear and then move the ring bevel gear away from the pinion in order to adjust the backlash. X -> Excessive contact at the tooth base: move the pinion away from the ring bevel gear and then approach the ring bevel gear to the pinion in order to adjust the backlash.

Movements to correct: 1 -> move the pinion for type X contact adjustment; 2 -> move the pinion for type Z contact adjustment.

37

Copyright © 38 DIFFERENTIAL LOCKING ASSY

Disassembly Loosen plug (1) without removing it.


Copyright © SECTION 27 - REAR AXLE Push the yoke (2) downwards using the differential support as a retainer, then remove the plug (1).

Insert tool 380200259.

Remove the snap ring (5). Remove tool 380200259.


39

Copyright © 40



Extract the rod assy (3) from the differential support.

Remove the yoke (2), the spring (7) and the spacer (8) from the rod (3).

Remove the O-ring (9) from the plug (1). Remove the O-rings (11) and (12) from the piston (10).

Copyright © SECTION 27 - REAR AXLE Assembly Assemble the O-rings (11) and (12) onto the piston (10). Assemble the O-ring (9) on the plug (1). Lubricate the O-rings.

Lubricate the rod (3). Assemble the yoke (2) on the rod (3). Assemble the spacer (8) and the spring (7). Orient the spacer (8) with the flat side towards the snap ring (13).

Assemble the rod assy (3) onto the differential support.

Assemble the spring (4).

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Copyright © 42


Assemble the bushing (6), making sure that its flat end faces outwards.

Insert tool 380200259 (T1).

Assemble the snap ring (5) with tool 380200260 (T2). Remove tools 380200259 (T1) and 380200260 (T2).

Push the yoke (2) downwards using the differential support as a retainer. Screw in the plug (1) by hand.

Copyright © SECTION 27 - REAR AXLE Tighten the plug (1) to the requested torque of 80 Nm (59 lbf·ft).

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Copyright © 44


DIFFERENTIAL

Disassembly If differential bearings must be replaced, remove the bearing cups (1) and (2). Remove the sleeve (3).

Copyright © SECTION 27 - REAR AXLE Remove the snap ring (4).

Take out the cover (5) and collect the anti-rotation pin (6) and the shoulder ring (7).


Remove the dowels (9).

45

Copyright © 46


Take out the pins (10).

Unscrew and remove the screws (11) and the ring gear (12).

Slip off pin (13) until the gear is free (14). NOTE: the pin can be slipped off only in one direction.

Assemble the planetary gear (14) and the relevant shoulder ring (15).

Copyright © SECTION 27 - REAR AXLE Remove the pin (13), the planetary gear (16) and the relevant shoulder ring (17).

Pull out partially the pins (18) and remove the spacer (19).

Remove the pins (18), the gears (20) and the relevant shoulder rings (21).

Remove the gear (22) and the relevant ring (23).

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Copyright © 48


Remove the pins (25) locking the differential box (24).

Assembly Assemble the O-rings (26) on the pins (25).

Assemble the pins (25) into the differential box (24).

Assemble the gear (22) and the relevant ring (23).

Copyright © SECTION 27 - REAR AXLE Assemble the gears (20) and the relevant shoulder rings (21). Insert pins (18) far enough to hold them. NOTE: orient the pins with the flat side upwards.

Assemble the spacer (19) and the pins (18), make sure to align the pin holes with those of the differential box (24).

Lubricate and assemble the gear (16) and the relevant shoulder ring (17). Insert pin (13). Orient the pin (13) with the flat side upwards.

Assemble the planetary gear (14) and the relevant shoulder ring (15) and insert the pin (13) and make sure to align the pin hole with that of the differential box (24).

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Copyright © 50


Assemble the ring gear (12), apply some sealant and tighten the screws (11) to a tightening torque of 165 Nm (122 lbf·ft).

Insert the pins (10) and tighten the plugs (9) to the prescribed torque.


Apply a thin film of grease on the cover (5) and assemble the ring (7).

Copyright © SECTION 27 - REAR AXLE Assemble the anti-rotation pin (6) on the cover (5). Assemble the cover (5) onto the differential box.

Lock the cover (5) with the snap ring (4).

Assemble the sleeve (3) and make sure that it seats correctly. NOTE: to ease the fitting, turn the gear (22).

Assemble the bearing cups (1) and (2) with drift 380200218. Take care not to mix the bearing cups.

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Copyright © 52


PINION ASSY

Disassembly Measure the starting preload FP0 of the pinion bearings using a dynamometer whose cord is wound on the end of the pinion shaft.

WARNING Note value FP0 that is necessary for assembling the bearings.

Measure the rolling torque MP0 of the bearings, using a torque wrench and tool 380200269.

WARNING Note value MP0 that is necessary for assembling the bearings.

Copyright © SECTION 27 - REAR AXLE Lock the differential assy in a vice. Unscrew the ring nut (1) using special tools 380000021 and 380000020. NOTE: this operation will irretrievably damage the lock nut (1).

Remove the ring nut (1) and collect its washer (2).

Tap the shaft end with a soft hammer to remove the pinion (3). Collect the washers (4) and (5), the spacer (6) and the bearing (7).

Remove the bearing cups (7) and (8) from the differential support (9) using a buffer and a hammer.

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Copyright © 54


Remove the bearing (8) from the pinion (3) by means of a puller. Collect the shim (10).

Check the conditions of all pinion parts. The ring nut (1) and the spacer (6) must be replaced during assembly.

Copyright © SECTION 27 - REAR AXLE Assembly Place the differential support (9) on a workbench. Insert the bearing cups (7) and (8) with the buffers 380200200 and 380002215 and a hammer.

Insert the bearings (7) and (8) into the relevant seats. Assemble the false pinion kit 380200273 (a1) and the ring nut (1). Tighten without exceeding the ring nut, until the backlash is eliminated.

Assemble tool 380200187 (T) on the differential box seats (9).

Use a depth gauge to measure dimension “X” (distance between bearing axis of differential box and leaning point of pinion head or bearing base).

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Copyright © 56


To adjust the bevel gear measure the distance “A” with a depth gauge. Determine the value “X” as follows: X = (A + C) - B mm (in) where “B” and “C” are known values.

In order to determine the value (S) of the shim to be placed between pinion and bearing, subtract from the measured value (X) the value (V) engraved on pinion head (V = prescribed distance). S = (X - V) mm (in)

Select the shim (10) with value (S) from the range of available shims, and fit it onto the shaft end under the pinion head. SHIM RANGE Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 mm (0.098) (0.102) (0.106) (0.110) (0.114) (0.118) (0.122) (0.126) (0.130) (0.134) (in) Q.ty

-

-

-

-

-

-

-

-

-

-

Remove tool 380200187 from the seats (9) of the differential box. Disassemble the ring nut (10), the false pinion 380200202 (a1) and the bearings (7) and (8).

Copyright © SECTION 27 - REAR AXLE Once you have chosen the suitable shim (10), insert it on the pinion shaft with the chamfer against the pinion head.

Insert the bearing (8) into the pinion (3) using a press and a buffer 380200204.

Insert the pinion (3) into the differential box (9). Insert the shims (4) and (5) and the spacer (6). NOTE: always use a new spacer (6).

Check the right assembly sequence.

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Copyright © 58


Assemble the bearing (7) on pinion shaft, using buffer 380200204 and a hammer.

Insert the washer (2) and tighten the new ring nut (1) on the pinion shaft. Lubricate the ring nut thread (1) and the supporting face with the washer (2) with oil.

Screw in the ring nut (1) using the wrench for ring nut 380200268 and the pinion retainer 380200269.

WARNING The tightening torque is given by the measure of the preload on bearings (7) and (8); gradually tighten the ring nut (1). NOTE: if the tightening is excessive, the spacer (6) must be replaced and the procedure repeated. When you check the preload, strike the pinion end (3) with a soft hammer to favour the bearings (7) and (8) settlement. If the bearings have not been replaced, to measure the preload FPm of the bearings (7) and (8), use a dynamometer whose cord is wound on the end of pinion shaft (3).

WARNING Use this method only if the bearings are not to be replaced, otherwise go to next step. The measured value should be within the following range: FPm = FP0 ÷ (FP0 + 10) N [FPm = FP0 ÷ (FP0 + 2.25) lbf]

Copyright © SECTION 27 - REAR AXLE If the bearings have not been replaced, it is possible to measure the rolling torque MPm of the bearings (7) and (8), using a torque wrench and tool 380000020. NOTE: use this method only if the bearings are not replaced.

WARNING All preloads must be measured without seal rings. The measured value should be the same of the starting: MPm = MP0 If the bearings (7) and (8) are new, to measure the preload FPm of the bearings, use a dynamometer whose cord is wound on tool 380200237, inserted on the end of pinion shaft.

The actual preload FPm is measured on tool 380200237 [gauge diameter Dm = 114.4 mm (4.50 in)]. The measured value should be within the following range: FPm = 38.3 ÷ 46 N [FPm = 8.61 ÷ 10.34 lbf]

WARNING Values for new bearings.

In case you do not use the prescribed tool to measure the preload, the reference diameter is the diameter of pinion shaft splined end. The measured value should be within the following range: FPm = 115 ÷ 138 N [FPm = 25.85 ÷ 31.02 lbf]

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Copyright © 60


If the bearings are new, measure the rolling torque MPm of the pinion shaft bearings with a torque meter and the wrench 380000020.


The measured value MPm should be within the following range: MPm = 2.0 ÷ 2.4 Nm [MPm = 1.47 ÷ 1.77 lbf·ft]

Once the prescribed preload value is achieved, caulk the ring nut (1) using a hammer and a punch.


61

TROUBLESHOOTING FAULT Wheel vibrations.

Tyre resistance.

Broken axle shaft.


No differential action; jams during steering.

POSSIBLE CAUSE

ACTION



Axle faulty.




Overload.




Axle beam bent.




Axle faulty.

Inspect and repair.



Overload.




Axle beam bent.




Axle faulty.

Inspect and repair.



Overload.




Axle beam bent.




Axle faulty.

Inspect and repair.



Overload.










Copyright © 62


FAULT Excessive noise.

Excessive wear of the tyre.

Friction noise.


POSSIBLE CAUSE

ACTION



Axle faulty.

Inspect and repair.



Overload.







Check that the structure and the bearings are in good conditions.





Axle faulty.

Inspect and repair.



Overload.






Differential locked.


Excessive steering angle.

Reduce the steering angle.








Replace the damaged axle parts.



Incorrect adjustment of the bevel gear set.

Adjust the bevel gear set.



Axle faulty.

Inspect and repair.






FAULT Outer tip of ring gear tooth is broken.


Crash load.

Replace bevel gear.

Gear adjustment wrong (insufficient backlash).

Follow carefully recommended adjustment operations of ring gear and pinion backlash and of tooth marks detection.


Replace bevel gear.

Contaminated lubricant.

Replace worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring gear.

Incorrect lubrication or poor additives. Worn out pinion bearings that cause an incorrect pinion axle backlash and wrong contact between pinion and ring gear. Ring gear teeth or pinion teeth overheated. Check if gear teeth have faded.

Replace bevel gear.

Pinion nut loose.

Pinion nut loose. Ring gear teeth or pinion teeth damaged or scored.

ACTION


Gear adjustment wrong (excessive backlash).

Inner tip of ring gear tooth is broken.

63

Prolonged operation at high temperature. Unsuitable lubricant. Oil level low.

Use proper lubricant, fill up to right level and replace at recommended intervals. Replace bevel gear. Use proper lubricant, fill up to right level and replace at recommended intervals.

Contaminated lubricant. Drive pinion teeth pitted.


Extremely intense use.

Replace bevel gear.


Use proper lubricant, fill up to right level and replace at recommended intervals.

Machine overloaded.


Damaged vehicle. Crash load. Bearings worn or pitted.





Extremely intense use. Normal wear. Pinion nut loose.

Copyright © 64


FAULT Gaskets leak oil.

POSSIBLE CAUSE

ACTION

Prolonged operation at excessive oil temperature.

Replace the gasket and matching surface if damaged.

Oil gasket wrongly installed.


Gasket edge cut or scored. Contaminated lubricant. Excessive wear of input flange spline.

Intense use.

Replace the flange.

Pinion nut loose.


Pinion axial backlash.

Replace bevel gear, if necessary. Pinion gear tooth fatigue break. Check if the fracture line is wavy or clearly delineated (stop line).

Intense use.

Break of pinion teeth and ring gear teeth.



Splines of planetary gear worn (excessive backlash).

Intense use.

Replace differential gear assy.

Worn or scored surfaces of the scraper thrust washer.



Replace axle beam, if necessary.

Lubrication wrong. Contaminated lubricant.

Inner diameter of pinion tapered roller bearing worn out.

Replace bevel gear.

Replace all scratched washers and those with a 0.1 mm (0.004 in) thickness lower than the new ones. Use proper lubricant, fill up to right level and replace at recommended intervals.

Intense use.

Replace bearing.

Excessive pinion end play.


Unsuitable lubrication.


Contaminated lubricant. Broken or bent axle beam.

Intense vehicle operation, overload.


Broken axle beam at wheel flange.




Check bending of axle beam body. Ensure that wheel support is not worn out or wrongly adjusted.


FAULT Noise during travel.

Noise during idling.

Intermittent noise.

Constant noise.

POSSIBLE CAUSE

65

ACTION

Excessive backlash between ring gear and pinion.

Adjust the backlash between the ring gear and the pinion.

Pinion and ring gear worn.

Replace pinion and ring gear.

Worn-out pinion bearings

Replace pinion bearings.

Loose pinion bearings.

Adjust pinion bearings.


Adjust the axial play of the pinion.

Differential bearings worn out.

Replace differential bearings.

Loose differential bearings.

Adjust the bearings.

Ring gear excessively off-set.

Replace the ring gear.

Low lubricant level.

Restore the level.

Poor or wrong lubricant grade.

Change lubricant.

Axle beam bent.


Noises emitted by the axle when the vehicle is moving are usually heard during idling, even though they are not too loud.

Adjust the backlash between the ring gear and the pinion or replace pinion and ring gear.

Wrong backlash between pinion and ring gear (the noise heard while decelerating disappears when speed is increased).

Adjust the play between the pinion and the ring gear.

Pinion spline or input flange worn.

Replace the pinion.

Damaged ring gear.

Replace bevel gear.



Ring gear teeth or pinion teeth damaged.

Replace bevel gear.

Worn bearings.


Pinion splines worn.

Replace the pinion.

Axle beam bent.


Copyright © 66


FAULT Noise while bending.

POSSIBLE CAUSE

ACTION

Differential planetary gears damaged.

Replace the planetary gears.

Differential box and/or pins worn.

Replace the differential box.

Worn differential thrust washers.

Replace the thrust washers.

Worn-out axle beam splines



67

REPAIR TIMES The times are referred to average values of maintenance performed by skilled personnel in workshops equipped with all necessary fixtures for a proper execution of the required works. The repair and/or replacement times are indicated in minutes. We assume that the axle has already been removed from the machine. ASSY Connection flange

OPERATION

TIME (minutes)

Pinion sealing ring

30

Replacement / overhauling of wheel flange (x 1)

240

Replacement of wheel hub with ring gear (x 1)

240

Replacement of bearings and wheel hub seal ring (x 1)

210

O-ring replacement (x 1)

30

Gear carrier assy replacement (x 1)

50

Replacement of discs and counterdiscs and zero setting of self-adjust (for each side)

40

Overhauling / replacement of brake piston seals (x 1)

90

Overhauling / replacement of brake cylinder (for each side)

105

Self-adjust replacement (for each side)

60

Axle shaft replacement (x 1)

30

Differential bearing replacement

180

Bevel gear / differential replacement

150

Differential

Differential gear replacement

240

Differential locking

O-ring / piston replacement

30

Pinion

Pinion bearings replacement

180

Wheel hub

Brake

Differential support

Copyright © 68



DESCRIPTION

USE

380002211

Handle


380000021

Wrench

Screw / unscrew the pinion ring nut

380200187

False differential box

Differential and pinion assembly

380002215

Buffer

Pinion bearing cups assembly

380000020

Wrench

Measure of pinion rolling torque

380002222

Buffer

Wheel hub seal ring and bearing assembly

380200200

Buffer

Pinion bearing cups assembly

380200202

False pinion


380200204

Buffer

Assembly of pinion bearings

380200211

Buffer


380200218

Buffer

Assembly of bearing cups into the differential box

380200228

Drift


380200237

Tool

Measure of pinion preload

380200243

Wrench

Screw / unscrew the pinion ring nuts

380200244

Wrench

Screw / unscrew the wheel hub ring nuts

380200245

Buffer

Assembly / disassembly of self-adjust kit

380200254

Buffer


380200255

Buffer

Assembly of bearings into gears

380200259

Plunger

Assembly / disassembly of differential locking yoke

380200260

Guide



2WS REAR AXLE (590ST) TECHNICAL SPECIFICATIONS

69

Copyright © 70


Manufacturer

CARRARO

Model

28.50


2.75/1


6.40/1


17.6/1

Input rotation

clockwise

Dry weight

472 kg (1040 lb)

Differential type Pressure for differential lock Bevel gear set backlash

Mechanical and driven 12 ÷ 35 bar (174 ÷ 508 psi) 0.20 ÷ 0.35 mm (0.008 ÷ 0.014 in)

Pinion bearing preload (*) (measured on Ø = 39.7 mm (1.56 in) without seal ring)

FPm = 10.0 ÷ 12.0 daN (22.48 ÷ 26.98 lbf)

Ring gear-pinion bearing total preload (*) (measured on Ø = 39.7 mm (1.56 in) without seal ring)

FTm = (FPm + 2.76) ÷ (FPm + 4.16) daN [FTm = (FPm + 6.20) ÷ (FPm + 9.35) lbf]

Pinion bearing rolling torque (*) measured without seal ring Total pinion-ring gear bearing rolling torque (*) measured without seal ring

MPm = 2.0 ÷ 2.4 Nm (MPm = 1.47 ÷ 1.77 lbf·ft) MTm = (MPm + 0.55) ÷ (MPm + 0.83) Nm [MTm = (MPm + 0.40) ÷ (MPm + 0.61) lbf·ft]

(*) Only for new bearings

SERVICE BRAKE

Brake type

Wet disc brake


-20 °C ÷ 150 °C (-4 ÷ 5.9 °F)


55 bar (798 psi)


A. New counterdisc thickness = 8.0 ± 0.05 mm (0.31 ± 0.002 in) B. New friction disc thickness = 6.73 ± 0.1 mm (0.26 ± 0.004 in) Worn disc minimum thickness = 5.8 mm (0.23 in) C. New counterdisc thickness = 5.0 ± 0.05 mm (0.20 ± 0.002 in)

16 cm 3 (0.98 in3)


71

LUBRICATION AND GREASING Oil capacity (differential) Oil type

1. Level and fill plug for differential oil 2. Differential oil drain plug 3. Oil breather 4. Oil drain plug 5. Brake breather

15.5 litres (3.41 gal) Akcela Transaxle fluid 80W -140

Copyright © 72





WARNING Risk of violent oil ejection. Drain all oil. Clean the plug (2), screw it and tighten to the prescribed torque of 80 Nm (59 lbf·ft). Fill through the hole of the plug (1). Check the level and, if necessary, top up. Clean the plug (2), screw it and tighten to the prescribed torque of 80 Nm (59 lbf·ft).

Copyright © SECTION 27 - REAR AXLE REMOVAL FROM MACHINE Move the machine to a level and firm ground, away from any soft ground, excavations and poorly shored cavity. Lower the loader attachment to the ground. Use the locking pin (if provided) to lock the loader attachment controls. Lower the backhoe attachment to the ground. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Lower the stabilizers until the rear wheels are slightly lifted from the ground (they are free from machine weight). Stop the engine and remove the starter key. Release the hydraulic pressure by operating the control levers in all directions. On hydraulically controlled machines, turn the key to ON and release the pressure by moving the hydraulic control levers in all directions. Disconnect the electric system by disconnecting the battery master switch. Fasten the rear axle to a lifting hoist or to a support. Now it is possible to carry out the disassembly of the 2 rear tyres by loosening and removing the relevant fixing nuts (9) [tightening torque = 700 Nm (516 lbf·ft)]. Disconnect the cardan joint (6) by unlocking and removing the screws (7) and the bracket (8). Unscrew and remove the screws (4) with the nuts (2) and the washers (3) and (5) [tightening torque = 610 ÷ 678 Nm (445 ÷ 500 lbf·ft)]. Remove the rear axle (1).

73

Copyright © 74


DISASSEMBLY AND ASSEMBLY Some of the following pictures could not exactly show your axle, but the procedure is correct. TIGHTENING TORQUES AND APPLICATION OF SEALANTS / ADHESIVES A. Loctite 510 B. Loctite 270 C. Loctite 638

Copyright © SECTION 27 - REAR AXLE GREASE POINTS

75

Copyright © 76


FRONT FLANGE

Disassembly Remove the stop ring (1) and the front flange (2). Collect shim (4) and the O-ring (3).

Take out the seal ring (5) from the central body (6).


Copyright © SECTION 27 - REAR AXLE If necessary, remove protection (7) from the front flange (2).

Assembly On the front flange (2), assemble the protection (7) using tool 380200277.

Use tool 380200277 to assemble the protection (7) on the front flange (2).

Insert a new seal ring (5) into the central body (6) using tool 380200276.

77

Copyright © 78


Use tool 380200276 to fit the seal ring (5) into the central body (6).

Grease the O-ring (3). Insert the washer (4), the O-ring (3) and the front flange (2) into the pinion. Fasten the pieces as soon as assembled by fitting the snap ring (1).

Copyright © SECTION 27 - REAR AXLE BRAKES


Loosen and remove all screws (1) except for 2 as a safety measure.

79

Copyright © 80


Connect the wheel hub (2) to a lifting device and tension the rope. Insert 2 opposed threaded rods to enable removal.

Remove the 2 last screws (1) and separate the wheel hub assy (2) from the axle body (3).

Slowly remove the wheel hub assy and the half axle (4), make sure that the discs (5) and the counterdiscs (6) stay on the wheel hub assy.

Place the wheel hub assy vertically and mark the counterdisc (5) assembled to the axle body side (3). Remove the discs (6), the counterdiscs (5) and the dowel pins (7).

Copyright © SECTION 27 - REAR AXLE Remove the half axle (4) from the wheel hub assy (2).

Remove the screws (8) and the belleville washers (9) from the brake cylinder (10).

Check screws (8) and belleville washers (9) for damage. NOTE: if brake discs are replaced, also replace screws and springs.

Remove the snap ring (11) and the self adjust kit assy (12).

81

Copyright © 82


Place the self adjust kit (12) on tool 380200245 and remove the snap rings (13).

Check bushing (14) for wear. Repeat the procedure for the remaining 2 self adjust kits.

Remove the brake cylinder assy (10).

Remove the brake piston (15) from the brake cylinder (10).

Copyright © SECTION 27 - REAR AXLE Remove the O-rings (16) and (17) from the brake cylinder (10).

Remove the O-ring (18) from the brake piston (15).


83

Copyright © 84


Assembly Assemble the new O-ring (19).

Assemble the O-ring (18) onto the brake piston (15).

Assemble the O-rings (16) and (17) onto the brake cylinder (10).

Lubricate the O-rings (16), (17) and (18). Assemble the brake piston (15) into the brake cylinder (10).

Copyright © SECTION 27 - REAR AXLE Lubricate the seat of the brake cylinder on the wheel hub (2) and assemble the dowel pins (7).

Assemble the brake cylinder assy (10) and remove the dowel pins (7).

Place the bushing (14) into tool 380200245 paying attention to direct it with the chamfer edge upwards.

Assemble the snap rings (13) by turning them by 90° with respect to the ring mounted before.

85

Copyright © 86


Assemble the snap rings (13) until they are seated against the calibrated disc and using a drift 380200245. Repeat the procedure for the remaining 2 self adjust kits.

Assemble the self adjust kits (12) into the brake cylinder, paying attention to direct the chamfer edge of the bushing (14) upwards.

Assemble the snap rings (11). Make sure that the teeth of the snap ring are directed towards the self adjust kit.

Snap ring (11) orientation.

Copyright © SECTION 27 - REAR AXLE Assemble the belleville washers (9) on the screws (8) paying attention to orient them correctly.

Assemble the screws (8) and the belleville washers (9). Tighten the screws (8) to a tightening torque of 15.3 Nm (11 lbf·ft). Make sure that the 4 belleville washers are correctly aligned before tightening the screws.

Assemble half shaft (4) and the dowel pins (7).

Using the reference mark made during disassembly, assemble the counterdisc (5) paying attention to direct it with the mark towards the axle body (3).

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Copyright © 88


Assemble the first braking disc (6) and the counterdisc (5). If using new brake discs (6), they must be soaked in oil for at least 24 hours prior to installation.

Assemble the last brake disc (6) and make sure that its slots are aligned with those of the first disc.

Connect the wheel hub (2) to a lifting device and assemble it on the beam (3). Support and turn the axle beam (4), while pushing the wheel hub onto it.

Screw in screws (1) applying the prescribed sealant and tighten to tightening torque of 226 Nm (167 lbf·ft).

Copyright © SECTION 27 - REAR AXLE WHEEL HUB

Disassembly Remove the brake assy.

If disassembly of the planetary gear carrier for overhauling is not necessary, use a bearing puller to lift the planetary gear carrier assy.

89

Copyright © 90


Enlarge the snap ring (2) and simultaneously extract the gear carrier (1).

If necessary, remove the snap rings (3) and by means of a puller the gears (4) with the bearings (5) from the gear carrier (1). NOTE: the bearing (5) cannot be removed from the gear (4). If one gear must be replaced, replace the whole pair.

Unscrew and remove the ring nut (6) fastening the ring gear retaining hub using tool 380200244.

Separate the hub (7) from the wheel flange (8) with a puller.

Copyright © SECTION 27 - REAR AXLE Connect the hub (7) to a hoisting tool to remove it. Collect the bearing (9).


Remove the seal ring (10) from the wheel hub (7).


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Copyright © 92


Remove the spacer (12) from the wheel flange (8).

To remove the bearing (11), use a disc grinder to cut the cage and to engrave the ring. Then use a chisel to cut and to remove the ring.

Assembly Assemble the bearing cup (11) onto wheel hub (7) with the buffer 380200211. Assemble the bearing cup (9) with the buffer 380002222. Assemble the seal ring (10) on the wheel hub (7) with the buffer 380200254.

Use tool 380200254 (T) to assemble the seal ring (10) onto the wheel hub (7).

Copyright © SECTION 27 - REAR AXLE Assemble the bearing (11) onto wheel flange (8) with a press.

Place the spacer (12) on the wheel flange (8).

Connect the wheel hub (7) to a lifting device and place it on the wheel flange (8). Clean the sealing surface of the flange. Pay attention not to damage the seal ring (10).

Assemble the bearing (9) and the ring nut (6).

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Screw in and tighten the ring nut (6) with tool 380200244 at tightening torque of 1000 Nm (738 lbf·ft).

Assemble the bearing (5) with tool 380200255 (T).

Assemble the gears (4) and the snap rings (3) on the gear carrier (1). Ensure that the chamfer of the bearings (5) is directed towards the gear carrier (1).

Connect the gear carrier (1) to a hoisting tool to remove it. Lift it and then place it on the wheel hub (7).

Copyright © SECTION 27 - REAR AXLE Orient the gear carrier so that the tooth engages into the ring nut (6).

In order to simplify the installation, align the hole on the gear carrier with the ring nut (6). NOTE: it may take several attempts to find the right combination of alignment between teeth and hole of the gear carrier and the ring nut, to get the locking tooth to engage.

Enlarge the snap ring (2) to complete the gear carrier (1) assembly.

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Copyright © 96


DIFFERENTIAL SUPPORT ASSY



Copyright © SECTION 27 - REAR AXLE Separate the axle support (3) from the axle body (2) using pry bars in slots.

Connect the differential support (3) to a lifting device to remove it.

Measure the rolling torque MT0 of the bearings (pinion-ring gear system), using wrench 380200269. Note value MT0 that is necessary for assembling the bearings. NOTE: the total rolling torque must be determined without the pinion seal ring.

It is possible to measure the total starting preload FT0 of the bearings (pinion-ring gear system) using a dynamometer whose cord is wound on the end of the pinion shaft. Note value FT0 that is necessary for assembling the bearings.

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Copyright © 98


Unscrew and remove the screws (4) fastening the ring nuts (5) and (6).

Unscrew the ring nuts (5) and (6) using tool 380200243.

Remove the differential box (7). The bearing cups (8) and (9) must be removed together with the differential box.

Copyright © SECTION 27 - REAR AXLE Assembly Assemble the bearing cups (8) and (9) on the differential box (7) with drift 380200218.

Assemble the differential box (7) with bearings onto the differential support (3).

Tighten both ring nuts (5) and (6) with special tool 380200243, till the backlash is eliminated and the bearings are slightly preloaded. Check that the bearings are correctly seated.

Position a magnetic-base dial gauge on the differential support, so that the feeler touches the surface of one tooth of the ring gear with a 90° angle.

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Copyright © 100


Lock the pinion and alternately move the ring gear, and note the backlash between pinion and ring gear, measured with the dial gauge. Repeat the operation on two or more points (teeth), rotating the ring gear, so that to obtain an average value. Check if the measured backlash value is within the requested range: 0.20 ÷ 0.35 mm (0.008 ÷ 0.014 in) Carry out the adjustment by operating on the ring nuts (5) and (6) with tool 380200243. Adjust the ring nuts (5) and (6), remembering that: - if the measured backlash is less than the prescribed tolerance range, unscrew the ring nut (6) and screw in the ring nut (5) by the same measure; - if the measured backlash is more than the prescribed tolerance range, unscrew the ring nut (5) and screw in the ring nut (6) by the same measure.

Repeat the whole sequence of the above mentioned operations until the requested conditions are reached.

Once the pinion-ring gear backlash has been adjusted, if the bearings have not been replaced, measure the total preload FTm of the bearings (pinion-ring gear system), using a dynamometer whose cord is wound on the end of the pinion shaft. Use this method only if the bearings are already run in. The measured value FTm should be within the following range: FTm = FT0 ÷ (FT0 + 10) N [FTm = FT0 ÷ (FT0 + 2.25) lbf]

Copyright © SECTION 27 - REAR AXLE Once the pinion-ring gear backlash has been adjusted, if the bearings have not been replaced, measure the total rolling torque MTm of the bearings (pinion-ring gear system) with a torque meter and the special wrench 380200269. The measured value MTm should be the same of the starting: MTm = MT0

If the bearings have been replaced, measure the total preload FTm of the bearings (pinion-ring gear system), using a dynamometer whose cord is wound on tool 380200272 inserted on the pinion splined end.

The total preload FTm is measured by tool 380200272. The measured value should be within the following range: FTm = (FPm + 9.2) ÷ (FPm + 13.8) N [FTm = (FPm + 2.07) ÷ (FPm + 3.10) lbf] where FPm is the actual preload measured on tool 380200272 [gauge diameter Dm = 119.1 mm (4.69 in)].

Once the pinion-ring gear backlash has been adjusted, if the bearings have been replaced, measure the total rolling torque MTm of the bearings (pinion-ring gear system) with a torque meter and the wrench 380200269.


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Copyright © 102


If the measure is not within the requested range, check the assembly of each component and operate on the ring nuts (5) and (6) of the differential support: - if the total preload is less than the given range, screw on the ring nuts (5) and (6) by the same measure, keeping the pinion-ring gear backlash value unchanged; - if the total preload is less than the given range, screw on the ring nuts (5) and (6) with the same measure, keeping the pinion-ring gear backlash value unchanged. NOTE: To test the marks of the bevel gear teeth, paint the ring gear with red lead paint. The contact mark test should always be carried out on the ring gear teeth and on both sides.

OK -> Correct contact: If the bevel gear is well adjusted, the mark on the teeth surfaces will be regular. Z -> Excessive contact on the tooth tip: approach the pinion to the ring bevel gear and then move the ring bevel gear away from the pinion in order to adjust the backlash. X -> Excessive contact at the tooth base: move the pinion away from the ring bevel gear and then approach the ring bevel gear to the pinion in order to adjust the backlash.

Movements to correct: 1 -> move the pinion for type X contact adjustment; 2 -> move the pinion for type Z contact adjustment.

Copyright © SECTION 27 - REAR AXLE Once all the adjustment operations have been completed, fit the ring nuts (5) and (6) by tightening the screws (4). Tighten the screws (4) to a tightening torque of 10 Nm (7.4 lbf·ft).

Before matching worked surfaces, make sure they are perfectly clean, if not, clean with proper detergents. Apply a film of sealant on the contact surface of the axle body (2) and the differential support.

Place the differential support (3) on the axle body (2).


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Copyright © 104 DIFFERENTIAL LOCKING ASSY

Disassembly Loosen plug (1) without removing it.


Copyright © SECTION 27 - REAR AXLE Push the yoke (2) downwards using the differential support as a retainer. Remove the plug (1).

Insert tool 380200259.

Remove the snap ring (5). Remove tool 380200259.


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Copyright © 106


Remove the plug (7).

Remove the springs (4) and (8) and the spacer (9).

Extract the rod assy (3) from the differential support.

Remove the O-ring (10) from the plug (1). Remove the O-rings (12) and (13) from the piston (11).

Copyright © SECTION 27 - REAR AXLE Remove the O-ring (14) from the plug (7).

Assembly Assemble the O-ring (14) on the plug (7).

Assemble the O-rings (12) and (13) onto the piston (11). Assemble the O-ring (10) on the plug (1). Lubricate the O-rings.

Assemble the rod (3) and the yoke (2) in the differential support. NOTE: orient the rod (3) with the outer groove (A) directed towards the yoke (2).

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Copyright © 108


Insert the springs (4) and (8) and the spacer (9).

Screw in and tighten the plug (1) to the prescribed torque of 80 Nm (59 lbf·ft).

Assemble the bushing (6).

Insert tool 380200259 (T1).

Copyright © SECTION 27 - REAR AXLE Assemble the snap ring (5) with tool 380200260 (T2). Remove tools 380200259 (T1) and 380200260 (T2).

Push the yoke (2) downwards using the differential support as a retainer. Screw in the plug (1) by hand.

Tighten the plug (1) to the prescribed torque of 30 Nm (22 lbf·ft).

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Copyright © 110 DIFFERENTIAL

Disassembly Loosen and remove the screws (1). Remove the ring gear (2).


Copyright © SECTION 27 - REAR AXLE If necessary, replace the differential bearings. Remove the bearing cups (3) and (4). Remove the sleeve (5).


Take out the cover (7) and collect the anti-rotation pin (8) and the ring (9).


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Copyright © 112


Remove the dowels (11).

Take out the pins (12).

Slip off pin (13) until the gear is free (14).

Assemble the gear (14) and the relevant shoulder ring (15).

Copyright © SECTION 27 - REAR AXLE Remove the pin (13), the gear (16) and the relevant shoulder ring (17).

Pull out partially the pins (18) and remove the spacer (19).

Remove the pins (18), the gears (20) and the relevant shoulder rings (21).

Remove the gear (22) and the relevant ring (23).

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Remove the pins (25) locking the differential box (24).

Assembly Assemble the O-rings (26) on the pins (25).

Assemble the pins (25) into the differential box (24).

Assemble the gear (22) and the relevant ring (23).

Copyright © SECTION 27 - REAR AXLE Assemble the gears (20) and the relevant shoulder rings (21). Insert pins (18) far enough to hold them. NOTE: orient the pins with the flat side upwards.

Assemble the spacer (19) and the pins (18), make sure to align the pin holes with those of the differential box (24).

Assemble the gear (16) and the relevant shoulder ring (17). Insert pin (13). Orient the pin (13) with the flat side upwards.

Assemble the gear (14) and the relevant shoulder ring (15) and insert the pin (13) and make sure to align the pin hole with that of the differential box (24).

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Copyright © 116


Insert the pins (12). Screw in and tighten the plugs (11) to the prescribed torque of 25 Nm (18.4 lbf·ft).


Apply a thin film of grease on the cover (7) and assemble the ring (9).

Assemble the anti-rotation pin (8) on the cover (7). Assemble the cover (7) onto the differential box.

Copyright © SECTION 27 - REAR AXLE Lock the cover (7) with the snap ring (6).

Assemble the sleeve (5) and make sure that it seats correctly. NOTE: to ease the fitting, turn the gear (22).

Assemble the bearing cups (3) and (4) with drift 380200218. Take care not to mix the bearing cups.

Assemble the ring gear (2). Apply some sealant and tighten the screws (1) to the prescribed torque of 190 Nm (140 lbf·ft).

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Copyright © 118


PINION ASSY

Disassembly Measure the starting preload FP0 of the pinion bearings using a dynamometer whose cord is wound on the end of the pinion shaft.


Measure the rolling torque MP0 of the bearings, using a torque wrench and tool 380200269.

WARNING Note value MP0 that is necessary for assembling the bearings.

Copyright © SECTION 27 - REAR AXLE Lock the differential assy in a vice. Unscrew the ring nut (1) using special tools 380200268 and 380200269. NOTE: this operation will irretrievably damage the lock nut (1).

Remove the ring nut (1) and collect its washer (2).

Tap the shaft end with a soft hammer to remove the pinion (3). Collect the washers (4) and (5), the spacer (6) and the bearing (7).

Remove the bearing cups (7) and (8) from the differential support (9) using a buffer and a hammer.

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Copyright © 120



Check the conditions of all pinion parts. The ring nut (1) and the spacer (6) must be replaced during assembly.

Copyright © SECTION 27 - REAR AXLE Assembly Place the differential support (9) on a workbench. Insert the bearing cups (7) and (8) with buffer 380200274 and a hammer.

Insert the bearings (7) and (8) into the relevant seats. Assemble the false pinion kit 380200273 (a1) and the ring nut (1). Tighten without exceeding the ring nut, until the backlash is eliminated.

Assemble tool 380200187 (T) on the differential box seats (9).

Use a depth gauge to measure dimension “X” (distance between bearing axis of differential box and leaning point of pinion head or bearing base).

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In order to determine the value (S) of the shim to be placed between pinion and bearing, subtract from the measured value (X) the value (V) engraved on pinion head (V = prescribed distance). S = (X - V) mm (in)

Select the shim (10) with value (S) from the range of available shims, and fit it onto the shaft end under the pinion head. NOTE: orient the shim (10) with the chamfered end towards the pinion head (3). SHIM RANGE Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 mm (0.098) (0.102) (0.106) (0.110) (0.114) (0.118) (0.122) (0.126) (0.130) (0.134) (in) Q.ty

-

-

-

-

-

-

-

-

-

-

Remove tool 380200187 from the seats (9) of the differential box. Disassemble the ring nut, the spacer, the false pinion 380200273 and the bearings (7) and (8).

Copyright © SECTION 27 - REAR AXLE Once you have chosen the suitable shim (10), insert it on the pinion shaft with the chamfer against the pinion head.

Insert the bearing (8) on the pinion (3) using a press and a buffer 380200220.

Insert the pinion (3) into the differential box (9). Insert the shims (4) and (5) and the spacer (6).


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Assemble bearing (7) on pinion shaft, using buffer 380200220 and a hammer.

Insert the washer (2) and tighten the new ring nut (1) on the pinion shaft. Lubricate the ring nut thread (1) and the supporting face with the washer (2) with oil.

Screw in the ring nut (1) using the wrench for ring nut 380200268 and the pinion retainer 380200269.

WARNING The tightening torque is given by the measure of the preload on bearings (7) and (8); gradually tighten the ring nut (1). NOTE: if the tightening is excessive, the spacer (6) must be replaced and the procedure repeated. When you check the preload, strike the pinion end (3) with a soft hammer to favour the bearings (7) and (8) settlement. If the bearings have not been replaced, to measure the preload FPm of the bearings (7) and (8), use a dynamometer whose cord is wound on the end of pinion shaft (3).

WARNING Use this method only if the bearings are not to be replaced, otherwise go to next step. The measured value should be within the following range: FPm = FP0 ÷ (FP0 + 10) N [FPm = FP0 ÷ (FP0 + 2.25) lbf]

Copyright © SECTION 27 - REAR AXLE If the bearings have not been replaced, it is possible to measure the rolling torque MPm of the bearings (7) and (8), using a torque wrench and tool 380200269. NOTE: use this method only if the bearings are not replaced.

WARNING All preloads must be measured without seal rings. The measured value should be the same of the starting: MPm = MP0 If the bearings (7) and (8) are new, to measure the preload FPm of the bearings, use a dynamometer whose cord is wound on tool 380200272, inserted on the end of pinion shaft.

The actual preload FPm is measured on tool 380200272 [gauge diameter Dm = 119.1 mm (4.69 in)]. The measured value should be within the following range: FPm = 33.3 ÷ 40 N (FPm = 7.49 ÷ 8.99 lbf)

WARNING Values for new bearings.

In case you do not use the prescribed tool to measure the preload, the reference diameter is the diameter of pinion shaft splined end. The measured value should be within the following range: FPm = 100 ÷ 120 N (FPm = 22.48 ÷ 2.02 lbf)

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If the bearings are new, measure the rolling torque MPm of the pinion shaft bearings with a torque meter and the wrench 380200269.


The measured value MPm should be within the following range: MPm = 1.6 ÷ 2.4 Nm (M Pm = 1.18 ÷ 1.77 lbf·ft)



127


Tyre resistance.

Broken axle shaft.


POSSIBLE CAUSE

ACTION



Axle faulty.




Overload.




Axle beam bent.




Axle faulty.

Inspect and repair.



Overload.




Axle beam bent.




Axle faulty.

Inspect and repair.



Overload.




Axle beam bent.




Axle faulty.

Inspect and repair.



Overload.






Copyright © 128


FAULT

POSSIBLE CAUSE

ACTION






Excessive noise.



Axle faulty.

Inspect and repair.



Overload.












Axle faulty.

Inspect and repair.



Overload.
























Axle faulty.

Inspect and repair.






Friction noise.





Crash load.

Replace bevel gear.




Replace bevel gear.




Replace bevel gear.

Pinion nut loose.


ACTION


Gear adjustment wrong (excessive backlash).


129






Replace bevel gear.



Machine overloaded.








Copyright © 130



POSSIBLE CAUSE

ACTION






Intense use.

Replace the flange.

Pinion nut loose.




Intense use.





Intense use.








Replace bevel gear.


Intense use.

Replace bearing.














FAULT Noise during travel.


Intermittent noise.

Constant noise.

POSSIBLE CAUSE

131

ACTION


















Restore the level.


Change lubricant.

Axle beam bent.







Replace the pinion.

Damaged ring gear.

Replace bevel gear.




Replace bevel gear.

Worn bearings.



Replace the pinion.

Axle beam bent.


Copyright © 132



POSSIBLE CAUSE

ACTION










133

REPAIR TIMES The times are referred to average values of maintenance performed by skilled personnel in workshops equipped with all necessary fixtures for a proper execution of the required works. The repair and/or replacement times are indicated in minutes. We assume that the axle has already been removed from the machine. ASSY Connection flange

OPERATION

TIME (minutes)

Pinion sealing ring

30

Replacement / overhauling of wheel flange (x 1)

240

Replacement of wheel hub with ring gear (x 1)

240

Replacement of bearings and wheel hub seal ring (x 1)

210


30

Gear carrier assy replacement (x 1)

50

Replacement of discs and counterdiscs and zero setting of self-adjust (for each side)

40

Overhauling / replacement of brake piston seals (x 1)

90

Overhauling / replacement of brake cylinder (for each side)

105

Self-adjust replacement (for each side)

60


30

Differential bearing replacement

180

Bevel gear / differential replacement

150

Differential

Differential gear replacement

240

Differential locking

O-ring / piston replacement

30

Pinion

Pinion bearings replacement

180

Wheel hub

Brake


Copyright © 134



DESCRIPTION

USE

380002211

Handle


380200268

Wrench


380200187



380002222

Buffer


380200269

Wrench


380200211

Buffer


380200218

Buffer


380200220

Buffer

Assembly of pinion bearings

380200272

Tool

Measure of pinion preload

380200273

False pinion


380200274

Buffer

Assembly of bearings into the differential box

380200243

Wrench

Screw / unscrew the pinion ring nuts

380200244

Wrench

Screw / unscrew the wheel hub ring nuts

380200245

Buffer


380200276

Buffer

Assembly of seal ring into front flange

380200254

Buffer

Disassembly of bearings and wheel hub seal ring

380200277

Buffer

Assembly of protection onto front flange

380200255

Buffer

Assembly of bearings into gears

380200259

Plunger


380200260

Guide



4WS REAR AXLE (695ST) TECHNICAL SPECIFICATIONS

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Copyright © 136


Manufacturer Model Maximum steering angle Toe-in

CARRARO 26.32M 21° 0-1 A±1


2.750/1


6.923/1


19.038/1

Input rotation

clockwise

Dry weight

538 kg (1186 lb)

Differential type

Limited slip or open

Bevel gear set backlash

0.15 ÷ 0.30 mm (0.006 ÷ 0.012 in)

Pinion bearing preload (*) (measured on Ø = 34.8 mm without seal ring)

FP = 92 ÷ 138 N (FP = 21 ÷ 31 lbf)

Ring gear-pinion bearing total preload (*) (measured on Ø = 34.8 mm without seal ring)

FT = (FP + 33.4) ÷ (FP + 50.2) N [FT = (FP + 7.5) ÷ (FP + 11.29) lbf]

Pinion bearing rolling torque (*) measured without seal ring Total pinion-ring gear bearing rolling torque (*) measured without seal ring (*) Only for new bearings

MP = 1.6 ÷ 2.4 Nm (MP = 1.18 ÷ 1.77 lbf·ft) MT = (MP + 0.58) ÷ (MP + 0.87) Nm [MT = (MP + 0.43) ÷ (MP + 0.64) lbf·ft]


137

SERVICE BRAKE

Brake type Brake actuation

Wet disc brake Hydraulic


-25 °C ÷ 150 °C (-13 ÷ 5.9 °F)


Mineral oil


Standard brake discs A. New counterdisc thickness = 5.0 ± 0.05 mm (0.20 ± 0.002 in) B. New friction disc thickness = 4.8 ± 0.05 mm (0.19 ± 0.002 in) Worn disc minimum thickness = 4.0 mm (0.16 in) C. New counterdisc thickness = 8.9 ÷ 9.0 mm (0.350 ÷ 0.354 in)

“Limited slip” brake discs A. New counterdisc thickness = 1.3 ± 0.03 mm (0.051 ± 0.001 in) B. New friction disc thickness = 1.6 ± 0.03 mm (0.063 ± 0.001 in) Worn disc minimum thickness = 1.4 mm (0.055 in) C. New friction disc thickness = 2.7 ± 0.05 mm (0.106 ± 0.002 in) Worn disc minimum thickness = 2.6 ± 0.05 mm (0.102 ± 0.002 in)

14 cm3 (0.85 in3)

Copyright © 138




1. Level and fill plug for differential oil 2. Differential oil drain plug 3. Oil breather 4. Filler, level and drain plug for reduction gear oil 5. Greasing points

Differential

11 litres (2.42 gal)

Final drive (each)



Copyright © SECTION 27 - REAR AXLE Before draining the oil from the axle body, use the breather (3) to release any possible internal pressure.



WARNING Risk of violent oil ejection. Drain all oil. Clean, screw and tighten the plug (2). Fill through the hole of the plug (1). Check the level and, if necessary, top up. Clean, screw and tighten the plug (1). Before draining the oil from the reduction gear, turn the gear so that the plug (4) is in the highest possible position [position A]. Partially unscrew the plug (4) to release any possible internal pressure. Turn the plug (4) and bring it to its lowest position [position B]. Remove the plug and drain the oil. Rotate again to bring the hole of the plug (4) to check and oil filling position (position C). Carry out the filling. Clean, screw in and tighten the plug (4).

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Copyright © 140


REMOVAL FROM MACHINE Move the machine to a level and firm ground, away from any soft ground, excavations and poorly shored cavity. Lower the loader attachment to the ground. Use the locking pin (if provided) to lock the loader attachment controls. Lower the backhoe attachment to the ground. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Lower the stabilizers until the rear wheels are slightly lifted from the ground (they are free from machine weight). Stop the engine and remove the starter key. Release the hydraulic pressure by operating the control levers in all directions. On hydraulically controlled machines, turn the key to ON and release the pressure by moving the hydraulic control levers in all directions. Disconnect the electric system by disconnecting the battery master switch. Fasten the rear axle to a lifting hoist or to a support. Now it is possible to carry out the disassembly of the 2 rear tyres by loosening and removing the relevant fixing nuts (9) [tightening torque = 700 Nm (516 lbf·ft)]. Disconnect the cardan joint (6) by unlocking and removing the screws (7) and the bracket (8). Unscrew and remove the screws (2) with the nuts (4) and the washers (3) and (5) [tightening torque = 830 ÷ 970 Nm (612 ÷ 715 lbf·ft)]. Remove the rear axle (1).

Copyright © SECTION 27 - REAR AXLE DISASSEMBLY AND ASSEMBLY Some of the following pictures could not exactly show your axle, but the procedure is correct. TIGHTENING TORQUES AND APPLICATION OF SEALANTS / ADHESIVES B. Loctite 270 C. Loctite 638

141

Copyright © 142


Copyright © SECTION 27 - REAR AXLE GREASE POINTS Tecnolube POLYMER 400 grease grease AGIP GR MU EP2

143

Copyright © 144


FRONT FLANGE

Disassembly Drain oil from the central body. Remove the snap ring (1) from the pinion shaft (6) and slip off the front flange (2).


Copyright © SECTION 27 - REAR AXLE Remove the O-ring (3). Collect the washer (4).

Assembly Insert the washer (4) into the pinion shaft. Assemble and lubricate the new O-ring (3).

Assemble the new seal ring (5) with tool 380200267 and a hammer.

Assemble the seal ring (5) by means of tool 380200267 (T1).

145

Copyright © 146 Assemble the front flange (2). Assemble the snap ring (1). Refill the central body with oil.


Copyright © SECTION 27 - REAR AXLE STEERING CYLINDER

Disassembly Loosen and remove the nuts (1) and (14) and slip off the tie rods (3) and (12) from the swivel housings (2) and (13).

WARNING Do not damage the end of the threaded pins. If necessary, replace the nuts (1) and (14).

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Copyright © 148


Remove the clamps (15) and (18). Disassemble the sensor (17), the connector bracket (16) and the 2 clamps (15) and (18).

Remove the tie rods (3) and (12) from the cylinder rods by loosening the nuts (4) and (11), then check their conditions. Remove the ball joints (5) and (9).

Loosen and remove the 2 screws (6) and the 2 screws (9). Take out the bushings (7) by means of a puller.

Remove the steering cylinder (8).

Copyright © SECTION 27 - REAR AXLE Remove the snap rings (19) and (27) from the steering cylinder (8).

Push the two cylinder heads (21) and (25) inside the cylinder.

Collect the 2 snap rings (20) and (26).

Pull out the rod (23) as necessary to collect the cylinder head (25). NOTE: do not extract the piston from the cylinder (22).

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Push the rod (23) in the opposite direction and remove it from the cylinder (22) with the head (21). Extract the head (21) from the rod (23).

Remove and, if necessary, replace all different seal rings from the rod (23) and from the 2 cylinder heads (21) and (25).

Assembly Assemble the seal rings (24) onto the 2 heads (21) and (25).

Assemble the seal rings (24) onto rod (23).

Copyright © SECTION 27 - REAR AXLE Check the proper assembly of the seal rings.

Assemble the 2 heads (21) and (25) with rod (23).

The 2 heads (21) and (25) must be positioned correctly.

Insert the pre-assembled assy, consisting in the rod (23) and the two cylinder heads (21) and (25) into the cylinder body (22).

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Push the cylinder heads (21) and (25) into the cylinder body (22).

Insert the 2 snap rings (20) and (26) into the relevant seats in the cylinder body (22).

Pull outward the rod (23) on each side pulling the cylinder heads (21) and (25) to the end of the stroke.

Assemble the 2 snap rings (19) and (27) on the heads (21) and (25).

Copyright © SECTION 27 - REAR AXLE Check the correct assembly of the heads and snap rings.

Assemble the steering cylinder (8).

Cool the bushes (7) down to a temperature lower than -100 °C (-148 °F) with liquid nitrogen. Assemble the bushes (7) by means of a punch and a hammer.

Screw in and tighten the screws (6) to a tightening torque of 220 Nm (162 lbf·ft). Screw in and tighten the screws (9) to a tightening torque of 660 Nm (487 lbf·ft).

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Screw in the ball joints (5) and (10) to the ends of the rod to the prescribed torque of 300 Nm (221 lbf·ft). Screw in the nuts (4) and (11) and the tie rods (3) and (12) to the ball joints (5) and (10).

Align the swivel housing (2) with the axle. Screw the tie rod (3) so that its ball joint can be inserted into the swivel housing (2) arm. It is important to unscrew the nut (4) to carry out this operation. Repeat the mentioned operations on the other side.

Insert the ball joint of the tie rod (12) into its seat on the swivel housing (13). Screw in and tighten the nut (14) to a tightening torque of 260 Nm (192 lbf·ft). Repeat the mentioned operations on the other side.

Screw in the nuts (4) and (11) of the tie rods (3) and (12) only after the toe-in adjustment has been carried out.

Copyright © SECTION 27 - REAR AXLE Assemble the sensor (17) and the connector bracket (16) with the clamps (15) and (18) to the steering cylinder (8).

Tighten the clamps (7) and (8) only after the toe-in adjustment has been carried out.

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STEERING SENSOR ADJUSTMENT

WARNING The steering sensor adjustment operations can be carried out only after toe-in adjustment has been carried out. Connect, by means of the relevant connector (C), the steering sensor (17) to a control device that can detect the presence of voltage generated by the sensor. The tool is usually provided with a led that turns on only when voltage is present.

Respect the steering sensor electric specifications and the connection diagram. It is also possible to use a common tester or to connect the steering sensor to the vehicle control panel. The picture shows the connector (C) diagram.

Align the wheels to rectilinear driving direction. Move the steering sensor (17) and relative clamps to a side of the cylinder. Fix the clamps (15) and (18) so that they can slide on the cylinder surface.

Copyright © SECTION 27 - REAR AXLE Slide horizontally the steering sensor till the led is on (position “A”) and measure XA dimension, between the differential support and the rear part of the sensor shown in the figure.

The red led (L) of the sensor (17) is located as illustrated.

Slide horizontally the steering sensor till the led is on (position “B”) and measure XB dimension, between the differential support and the rear part of the sensor.

Move the steering sensor backwards by a distance of (XB - XA)/2 as shown in the figure [maximum tolerance ± 1.0 mm (0.04 in)].

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Before tightening the hose clamps, check the right position of the steering sensor (17) in the appropriate seat fixed on the steering cylinder (the steering sensor must be oriented as shown in the figure).

Position the fastening screws (S) of the 2 hose clamps (15) and (18). Tighten the fastening screws (S) to lock the sensor (17).

Copyright © SECTION 27 - REAR AXLE REDUCTION GEAR

Disassembly Unscrew the plug (1) and drain oil from the reduction gear.

Loosen and remove the 2 fixing screws (2).

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Remove the gear carrier (3) from the wheel hub (10) and remove the relevant O-ring (9). Position the gear carrier (3) on a workbench and check its wear conditions.

To carry out any possible replacement of the gears (6): - loosen and remove the screw (8) of each gear (6); - remove the washer (7); - take out the gears (6) from the pins; - collect the bearings (5) and check their conditions; - collect the thrust washer (4).

Assembly Collect all reduction gear parts: the gear carrier, the thrust washers (4), the gears (6) with the relevant needle bearings (5), the washers (7) and the screws (8). With new gears (6), it is advisable to assemble new bearings (5).

Position the planetary gears carrier (3) on a workbench. Insert the needles (5) into the gears (6). Grease the needles (5). Insert the pin of the planetary gear carrier (3), the thrust washer (4) and the gears (6) with needles.

Copyright © SECTION 27 - REAR AXLE Assemble the washers (7) into the pins of the planetary gear carrier (3). Screw in and tighten the screws (8) to a tightening torque of 79 Nm (58 lbf·ft).

Install the new O-ring (9) on the wheel hub (10).

Assemble the reduction gear assy on the wheel hub. Screw in and tighten the screws (2) to a tightening torque of 25 Nm (18.4 lbf·ft).

Refill the epicyclic reduction gear with oil. Screw in and tighten the plug (1) to the tightening torque of 60 Nm (44 lbf·ft).

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WHEEL HUB

Disassembly Insert a lever between the swivel housing and the axle body and fit it into the double joint. With the lever push the double joint in the direction of the wheel hub to allow the snap ring removal. Do not damage the double joint.

Copyright © SECTION 27 - REAR AXLE Remove the snap ring (1). Collect the washer (2) and the thrust washer (3).


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

Remove the snap ring (8) and separate the ring gear carrier hub (7) from the ring gear (4). Only if necessary, remove the centering bushes (6) from the ring gear carrier by means of tool 380200192 and a hammer.

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Remove the wheel hub (11) from the swivel housing (14) and collect the bearing (9).

Slide out the wheel hub (11), using levers and a hammer to facilitate the operation.

Position the wheel hub (11) on a flat surface and remove the seal ring (13). Take out the bearing cups (9) and (12) with a drift and a hammer.

Remove the bearing (12) from the swivel housing (14) by means of a puller.

Copyright © SECTION 27 - REAR AXLE Unscrew and remove the screws (15) and (19) from the upper (16) and lower (18) king pins.

DANGER Before removing the king pins (16) and (18), secure the swivel housing (14) with a rope or a hoist or any other supporting device to guarantee operator’s safety. Remove the king pins (16) and (18).

Loosen and remove the swivel housing (14).

Position the swivel housing (14) on a flat surface and take the seal ring (25) out with a puller. Rivet the swivel housing and take out the bronze bushing (24), using a buffer and a hammer.

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Assembly If previously removed, assemble the steering stop screw (23), the nut (22) and the bushings (20) and (21). Do not tighten the nut (22) until the steering angle adjustment has been carried out.

Insert the bronze bushing (24) into the swivel housing (14) by means of tool 380000024 and a hammer. Assemble the new seal ring (25) into the swivel housing (14) with tool 380200266 and a hammer.

If the ball bearing (17) has been previously removed, reassemble it to the lower king pin (18) by means of tool 380200195 and a press. Grease the king pin seats (16) and (18). Position the belleville washers (27) and (28) on the king pin seats (16) and (18).

Secure the swivel housing (14) with a rope to a hoist or any other supporting device. Protect the splined end of the axle shaft by winding it with protective tape, to avoid damaging the seal ring. Assemble the swivel housing (14) to the axle and, after assembly, completely remove the protective tape.

Copyright © SECTION 27 - REAR AXLE Assemble the lower (18) and the upper (16) king pins. Screw in and tighten the screws (19) and (15) to the prescribed torque of 300 Nm (221 lbf·ft). Make sure that the belleville washers stay in the correct position.

The special operation “Set Right” of the bearings does not require preload or backlash adjustment. Anyway, before assembling new components, check the indicated dimensions. A = 10.090 ÷ 10.140 mm (0.397 ÷ 0.399 in) B = 64.275 ÷ 64.325 mm (2.530 ÷ 2.532 in) C = 27.000 ÷ 27.100 mm (1.063 ÷ 1.066 in)

Insert the bearing cups (9) and (12) into the wheel hub (11) by means of tool 380200211 and a press. Insert the new seal ring (13) into the wheel hub (11) using tool 380200210 and a hammer. Lubricate the seal ring (13).

Assemble the bearing (12) in the swivel housing (14). Assemble the wheel hub (11) on the swivel housing (14) and fit the bearing (9).

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Position the ring gear hub (7) on a workbench and insert the bushings (6) at surface level with tool 380200192. At least two bushings (diametrically-opposed) should be set slightly higher than the carrier surface level to be used as dowel pins.

Preassemble the ring gear carrier hub (7) and the ring gear (4) with the snap ring (8).

Assemble the ring gear carrier hub assy on the wheel hub using the two projecting bushings as dowel pins. Screw the relevant screws in order to put in contact the assembly with the wheel hub.

Assemble all bushings (6) up to stroke end with tool 380200192 and a hammer. Screw in and tighten the screws (5) to a tightening torque of 230 Nm (170 lbf·ft).

Copyright © SECTION 27 - REAR AXLE Insert a lever between the swivel housing (14) and the axle body and fit it into the double joint. With the lever push the double joint in the direction of the wheel hub to allow the snap ring introduction.

Insert the thrust washer (3) and the washer (2). Assemble the snap ring (1) at the end of the splined hub.

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BEAM ASSY

Disassembly Drain axle oil completely. Loosen and remove the two screws (13). Unscrew the nuts (11) of the oil recirculation line (12).

Copyright © SECTION 27 - REAR AXLE Remove the oil recirculation line (12).

If necessary, remove the cover (1) from the double joint (2).

Remove the double joint (2).

Put alignment marks on the beam trumpets, on the brake cylinders and on the axle central body, in order to identify the coupling parts during reassembly.

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Position the axle on supports suitable to hold it or secure the assemblies separately to a lifting device. Loosen and remove the screws (7).

Remove the beam (8) and the O-ring (9). If the beam is removed, the brake assy is released.

Extract the seal ring (3). If necessary, remove the bushing (4), paying attention not to damage its seat.

If necessary, remove the bushing (5) and the race (6) of the ball joint from the seats using a puller.

Copyright © SECTION 27 - REAR AXLE Assembly Cool down the bushing (5) and the cup (6) to a temperature lower than -100 °C (-148 °F) with liquid nitrogen. Assemble the bushing (5) in the upper king pin seat with buffer 380200196 and a hammer. Assemble the cup (6) on the lower king pin seat with buffer 380200196 and a hammer.

Assemble the bushing (4) by means of tool 380200227 and a hammer. Assemble a new seal ring (3) by means of tool 380002226. Lubricate the seal ring.

Correctly orient the seal ring (3).

Assemble the new O-ring (9) on the beam (8).

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Support the assemblies properly as already pointed out for disassembly phase. Assemble the beam (8) on the central axle body (10) respecting the reference marks applied during disassembly.


Tighten the screw (7) respecting the sequence shown.

Insert the double joint (2). Be careful not to damage the seal ring.

Copyright © SECTION 27 - REAR AXLE Assemble the oil recirculation line (12).

Screw in and tighten the screws (13) to a tightening torque of 23 Nm (17 lbf·ft). Tighten the nuts (11) to the tightening torque of 60 Nm (44 lbf·ft).

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Copyright © 176 BRAKES

Disassembly Remove the beam and the axle shaft.


Copyright © SECTION 27 - REAR AXLE Remove the brake components: the counterdiscs (11), discs (12), the brake disc carrier hub (10), the brake disc (9) and the brake counterdisc (8). NOTE: mark the position of the hub for assembly.

Remove the brake piston return kit (7) and the selfadjust kit (6).

Take out the brake piston (4) from the brake cylinder (1). If necessary, remove the plug (14) and the relevant O-ring (13).

Blow some air through the oil supply hole for the brake to eject the piston (4), using the minimum pressure required.

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Remove the O-rings (2) and (3) from the piston (4).

If necessary, remove the bushings (5) of the selfadjust kit from the piston (4), using tool 380200194 and a hammer.

Assembly Collect the piston (4). Push the washers (5) into the self-adjust seats using tool 380200194 and a hammer, till they are aligned with the piston supporting inner surface.

The bushings (5) must be aligned with the inner supporting surface of the piston (4).

Copyright © SECTION 27 - REAR AXLE Assemble the new O-rings (2) and (3) into the piston (4). Lubricate the O-rings.

Insert the piston (4) into the brake cylinder (1).

Place tool 380200238 onto the piston (4). Place the piston (4) with one slot aligned with the oil recirculation hole or with the brake inspection hole in the brake cylinder (1). Use a prybar to insert the piston into the brake flange with a light pressure.

Insert the big spring, the small spring and the bushing of the piston return kit (7) into the bigger hole of the piston.

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Assemble the cover and the screw of the piston return kit (7).

Assemble the bushing, the washer and the screw of the self-adjust kit (6).

Screw and tighten the screws of the 2 kits.

If you are to replace the brake discs, you have to restore the initial piston position. Remove the connections, the breathers and possible plugs from the brake oil inlets.

Copyright © SECTION 27 - REAR AXLE Bring the piston (4) to stroke end, using tool 380200238 and a hammer. Place the tool carefully so as not to damage the piston.

Check that the brake discs and the counterdiscs do not show any sign of burning (otherwise replace them). If new brake discs are installed, soak them into prescribed oil before assembly.

Reassemble all elements of the brake assy: the brake counterdisc (8), the brake disc (9), the brake disc carrier hub (10), the counterdiscs (11) and the discs (12).

Orient the teeth correctly i.e. to the outside of the brake disc carrier hub (10).

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Reassemble the beam with the axle central body.

BRAKE DISC REPLACEMENT Remove the wheel hub assy from the axle.

Remove the beam.

Copyright © SECTION 27 - REAR AXLE Remove the brake components: the counterdiscs (11), discs (12), the brake disc carrier hub (10), the brake disc (9) and the brake counterdisc (8).

Check that the brake discs and the counterdiscs do not show any sign of burning (otherwise replace them). If new brake discs are installed, soak them into prescribed oil before assembly.

If you are to replace the brake discs, you have to restore the initial piston position. Remove the connections, the breathers and possible plugs from the brake oil inlets.

Bring the brake piston (4) to stroke end, using tool 380200238 and a hammer. place the special tool carefully so as not to damage the piston.

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Reassemble all brake elements: the brake counterdisc (8), the brake disc (9), the brake disc carrier hub (10), the counterdiscs (11) and the discs (12).

Orient the teeth correctly i.e. to the outside of the brake disc carrier hub (10).

Reassemble the beam with the axle central body.

Copyright © SECTION 27 - REAR AXLE DIFFERENTIAL SUPPORT

Disassembly Remove the brake.

Measure the starting preload FT0 of the bearings (pinion-ring gear system) using a dynamometer whose cord is wound on the end of the pinion shaft. Note value FT0 that is necessary for assembling the bearings.

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Ensure the brake cylinder (6) to a lifting device using its holes. Loosen and remove the screw (7).

Remove the brake cylinder (6). This operation releases the differential assy. Disassemble the brake cylinder (6) and remove the relevant O-ring (4). Remove the O-ring (2).

Remove the differential (3) from the central body (1).

Unscrew and remove the screw (10) and the ring nut retainer (9) from the brake cylinder (6).

Copyright © SECTION 27 - REAR AXLE Unscrew and remove the ring nut (8) from the brake cylinder (6) using tool 380200209.

Pull out the bearing cup (5) from the brake cylinder (6) using a buffer and a hammer.

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Assembly Before assembling the differential, install the pinion assy.

Lubricate and insert the new O-ring (2) on each side of the central body (1).

Place the brake cylinder (6) on a flat surface and force the bearing cup (5) using buffer 380200218.

Measure the outer diameter C of the ring gear installed on the differential. Calculate the value: R = C/2 mm (in) NOTE: this datum is required for the backlash adjustment between pinion and ring gear.

Copyright © SECTION 27 - REAR AXLE Lubricate or assemble a new O-ring (4) into the seat of the 2 brake cylinders (6).

Assemble the left brake cylinder into the central body (1). Check that the reference marks applied during disassembly between the brake cylinders and the central body coincide. Insert the differential (3) into the central body (1). The ring gear must be placed on the left side.

Assemble the right brake cylinder (6) into the central body (1). Check that the reference marks applied during disassembly between the brake cylinders and the central body coincide.

Tighten screw (7) in place (A). Tighten the screw to the prescribed torque of 80 Nm (59 lbf·ft). Screw in the 2 screws M16 x 130 (S) in place (B) and tighten them to the 80 Nm (59 lbf·ft) torque.

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Tighten both ring nuts (8) with tool 380200209, till the backlash is eliminated and slightly preload the differential bearings.

Assemble tool 380200222 on the hole of the differential box. Place a dial gauge and a feeler in contact and to 90° with respect to the surface of the tool and in correspondence of value R.

Shift manually and alternately tool 380200222 bracket installed on the hole of the differential box. Determine and note the backlash between pinion and ring gear. Turn the ring gear 1/4 of turn, determine and note the backlash between pinion and ring gear. Repeat this operation to get several values of the backlash. Check if the average backlash is within the requested range: 0.15 ÷ 0.30 mm (0.006 ÷ 0.012 in) If the backlash is not within the requested range, carry out adjustment as follows. Adjust the ring nuts (8) with tool 380200209. Unscrew and tighten both ring nuts of about 30° each, then check the backlash.

Copyright © SECTION 27 - REAR AXLE Adjust the ring nuts (8) remembering that: - if the measured backlash is higher than the prescribed tolerance range, tighten the ring nut on the opposite side of the ring gear and loosen the opposite ring nut by the same measure (A); - if the measured backlash is lower than the prescribed tolerance range, tighten the ring nut on the ring gear side and loosen the opposite ring nut by the same measure (B).

After pinion-ring gear backlash adjustment, check that there is a minimum preload on the differential box bearings. Repeat the whole sequence of the above mentioned operations until the indicated conditions are reached.

Once the pinion-ring gear backlash has been adjusted, if the bearings have not been replaced, measure the total preload FTm of the bearings (pinion-ring gear system), using a dynamometer whose cord is wound on the end of the pinion shaft. Use this method only if the bearings are already run in. The measured value FTm should be within the following range: FTm = FT0 ÷ (FT0 + 10) N [FTm = FT0 ÷ (FT0 + 2.25) lbf] If the bearings have been replaced, measure the total preload FTm of the bearings (pinion-ring gear system), using a dynamometer whose cord is wound on tool 380200237 inserted on the pinion splined end.

WARNING All preloads must be measured without seal ring.

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The total preload FTm is measured by tool 380200237. The measured value should be within the following range: FTm = (FPm + 11.1) ÷ (FPm + 16.7) N [FTm = (FPm + 2.5) ÷ (FPm + 3.7) lbf] where FPm is the actual preload measured on tool 380200237 [gauge diameter Dm = 104.4 mm (4.11 in)].

NOTE: if you do not use the prescribed tool to measure the total preload FTm, the reference diameter is the diameter of pinion shaft splined end. The measured value should be within the following range: FTm = (FPm + 33.4) ÷ (FPm + 50.2) N [FTm = (FPm + 7.5) ÷ (FPm + 11) lbf] where FPm is the preload of the pinion bearings.

Once the pinion-ring gear backlash has been adjusted, if the bearings have been replaced, measure the total rolling torque MT of the bearings (pinion-ring gear system) with a torque meter and the wrench 380000020.


The total torque MT should be within the following range: MTm = (MP + 0.58) ÷ (MP + 0.87) Nm [MTm = (MP + 0.43) ÷ (MP + 0.64) lbf·ft] where MP is the preload of the pinion bearings.

Copyright © SECTION 27 - REAR AXLE If the measure is not within the requested range, check the assembly of each single component and operate on the ring nuts of the differential support: - if the total preload is less than the given range, screw on the adjusting ring nuts by the same measure, keeping the pinion-ring gear backlash value (A) unchanged; - if the total preload is more than the given range, unscrew the adjusting ring nuts by the same measure, keeping the pinion-ring gear backlash value (B) unchanged.

Once all adjustment operations have been performed, assemble the ring nut retainers (9), fastening them with the relevant screws (10). Tighten the screws (10) to a tightening torque of 13 Nm (9 lbf·ft). Turn the ring nuts (8) as little as possible to allow their assembly.

Remove the 2 additional screws M16 x 130 (S) from both sides.

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NON-SELF-LOCKING DIFFERENTIAL

Disassembly Lock the differential with a clamp. Loosen the screws (1) and remove the ring gear (2). This operation releases also the two half boxes of the differential.

Copyright © SECTION 27 - REAR AXLE Disassemble the 2 half boxes (4) and (12). Apply reference marks on the 2 half boxes before separating them. Disassemble all parts and check their operating status and wear condition.

Take out the bearings (3) and (13) from the half boxes (4) and (12) using a puller.

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Assembly Assemble the bearings (3) and (13) on the half boxes (4) and (12), using tool 380200188 and a hammer.

Place the half boxes (4) and (12) on a workbench and carefully assemble the inner elements: the differential locking counterdiscs (5), the gear (6), the 2 pins (7), the planetary gears (8) and the thrust washers (9). Join the two half boxes (4) and (12), aligning the reference marks made during disassembly.

Before matching worked surfaces, make sure they are perfectly clean, if not, clean with proper detergents. Place the ring gear (2) on the differential box. Apply sealant on the screw thread (1). Screw in and tighten the screws (1) to a tightening torque of 155 Nm (114 lbf·ft).

Copyright © SECTION 27 - REAR AXLE “LIMITED SLIP” DIFFERENTIAL

Disassembly Lock the differential with a clamp. Loosen the screws (1) and remove the ring gear (2). This operation releases also the two half boxes of the differential.

Disassemble the 2 half boxes (4) and (12). Apply reference marks on the 2 half boxes before separating them. Disassemble all parts and check their operating status and wear condition.

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Take out the bearings (3) and (13) from the half boxes (4) and (12) using a puller.

If necessary, take out the bushings (14) from the half boxes (4) and (12). Do not damage the bushing seats.

Copyright © SECTION 27 - REAR AXLE Assembly If previously removed, insert bushings (14) into the half boxes (4) and (12) using tool 380200205 and a hammer.

Assemble the bearings (3) and (13) on the half boxes (4) and (12), using tool 380200188 and a hammer.

Place the half boxes (4) and (12) on a workbench and carefully assemble the inner elements: differential locking counterdiscs (5), differential locking discs (6) and (7), gears (8), 2 pins (9), planetary gears (10) and thrust washers (11). The first disc (7) must be oriented with friction face towards the discs and with smooth face towards the gear (8). Join the 2 half boxes (4) and (12), aligning the reference marks made during disassembly.

Before matching worked surfaces, make sure they are perfectly clean, if not, clean with proper detergents. Place the ring gear (2) on the differential box. Apply sealant on the screw thread (1). Screw in and tighten the screws (1) to a tightening torque of 155 Nm (114 lbf·ft).

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PINION

Disassembly Remove the differential assy. Measure the starting preload FP0 of the pinion bearings using a dynamometer whose cord is wound on the end of the pinion shaft.


Unscrew the ring nut (10) using wrench (T1) and pinion retainer (T2) 380000020 with 3/4” standard connection.

Copyright © SECTION 27 - REAR AXLE Tap the shaft end with a soft hammer to remove the pinion (1).

Once the pinion (1) has been removed, collect the washers (4), (6) and (9), the spacer (5) and the bearing (8).

Check the wear condition of the bearing cups. Take out the bearing cups (3) and (8), if necessary.


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Check the conditions of all parts. The ring nut (10) and the spacer (5) must be replaced during reassembly.

Assembly Position the axle central body onto a workbench. Insert the bearing cups (3) and (8) into their seats using kit 380200216.

Use the false pinion 380200202 and false differential box 380200217. Insert the bearing and the false pinion into the seats. Tighten the ring nut, until the backlash is eliminated.

Check the correct place of the differential box supports at the right and left side, using the reference marks applied on the same and on the central body. Assemble the 2 brake cylinders, fastening them with the relevant screws.

Copyright © SECTION 27 - REAR AXLE Insert the false differential box 380200217 into the central axle body. Check that the false differential box is inserted in both seats of the differential supports.


From the value “X” deduct the value “V” (stamped on the pinion head) to get the value “S”. S = X - V mm (in)

Choose the shim with value (S) from the shim range available. SHIM RANGE Shims 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 mm (0.098) (0.102) (0.106) (0.110) (0.114) (0.118) (0.122) (0.126) (0.130) (0.134) (in) Q.ty

-

-

-

-

-

-

-

-

-

-

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Loosen and remove the ring nut (10). Remove the false pinion 380200202 and the bearings (3) and (8) from the central body (7). Disassemble the false differential box 380200217 from the brake cylinders and then unscrew the screws to remove the brake cylinders.

Once you have chosen the suitable shim (2), insert it on the pinion shaft with the chamfer against the pinion head.

Insert the bearing (3) on the pinion shaft (1) using a press and tool 380200190. Insert the shim (4) and a new spacer (5) and the shim (6).


Copyright © SECTION 27 - REAR AXLE Insert the preassembled pinion (1) into the central body and the bearing (8) into the pinion shaft. Assemble the bearing (8) with tool 380200190 and a hammer.

Insert the ring nut retaining washer and tighten the new ring nut (10) on the pinion shaft. Tighten the ring nut (10) using wrench (T1) 380000021 and the pinion retainer (T2) 380000020 with 3/4” standard connection. The torque setting is given by the preload measurement on bearings. Tighten the ring nut (10) gradually. Excessive tightening could damage the spacer (5), that would need to be replaced and the procedure to be repeated. When you check the preload, strike the pinion ends (1) with a soft hammer to favour the seating of the bearings. If the bearings have not been replaced, to measure the preload FPm, use a dynamometer whose cord is wound on the end of the pinion shaft.

WARNING Use this method only if the bearings are not replaced. The measured value should be within the following range: FPm = FP0 ÷ (FP0 + 10) N [FPm = FP0 ÷ (FP0 + 2.25) lbf]

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If the bearings are new, to measure the preload FPm, use a dynamometer whose cord is wound on tool 380200237, inserted on the end of pinion shaft.

The actual preload FPm is measured on tool 380200237 [gauge diameter Dm = 114.4 mm (4.50 in)]. The measured value should be within the following range: FPm = 31 ÷ 46 N [FPm = 6.97 ÷ 10.34 lbf]

In case you do not use the prescribed tool to measure the preload, the reference diameter is the diameter of pinion shaft splined end. The measured value should be within the following range: FPm = 92 ÷ 138 N [FPm = 20.68 ÷ 31.02 lbf]

It is possible to measure the rolling torque MP of the pinion shaft bearings with a torque meter and the wrench 380000020.


Copyright © SECTION 27 - REAR AXLE The measured value MP should be within this range: MP = 1.6 ÷ 2.4 Nm [MP = 1.18 ÷ 1.77 lbf·ft]


Assemble the differential assy (3).

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TOE-IN / STEERING ANGLE

Toe-in check Assemble 2 identical, 1 m long linear bars on the wheel sides and lock them with 2 nuts on the wheel hub stud screws.

WARNING The 2 bars should be fixed on their middle so that they are perfectly perpendicular to the supporting surface and parallel to the pinion axis; align the 2 bars.

Measure with a tape measure the distance (M) between bar ends. NOTE: keep the minimum value, swinging the measurement point.

Copyright © SECTION 27 - REAR AXLE Check that the difference between the measurements at the ends of the wheel hub diameters is within the required tolerance range. The nominal toe-in (A) value is referred to the external diameter of the wheel hubs flange, therefore the measured toe-in value (M) at the bar ends must be related to the ratio between length of the bar and flange diameter: nominal toe-in = A±1

measured toe-in = M±3

If toe-in is not correct, operate with two wrenches on the rods (1) screwing in and out the two tie rods (3) equally, till the toe-in is within the requested tolerance.

Once this adjustment has been performed, screw in the nuts (2) of the bars (1) and tighten them to a 250 Nm (184 lbf·ft) torque.

209

Copyright © 210


Steering angle adjustment Use the same bars assembled for toe-in adjustment and a long bar perfectly rested on the machined part of the central body (pinion side), so that, at maximum steering, the two bars form an acute angle.

In order to set the steering angle, adjust a goniometer according to the angle measure (C), calculated as follows: C = 90° - S Where (S) is the prescribed steering angle set. Place the goniometer on the long bar. Orient the left wheel assy until the calculated angle (C) is obtained between the two bars.

Apply the prescribed sealant on the screw thread (4). Carry out the adjustment of the mechanical lock, screwing in and out the relevant screws (4), locking them afterwards with the nuts (5). Tighten to the prescribed torque of 150 Nm (111 lbf·ft).

Check that the locks on the opposite sides are both in contact with the axle beam.

Copyright © SECTION 27 - REAR AXLE Completely steer to the opposite side and repeat the same operations described previously.

Check that the locks on the opposite sides are both in contact with the axle beam.

211

Copyright © 212


SPECIAL INTERVENTIONS

Disassembly of wheel assy and double joint Drain the oil from the differential. Loosen and remove the nut (1) and disconnect the tie rod (3) from the swivel housing.

WARNING Do not hit the end of the threaded pin of the tie rod (3) during disassembly.

Do not unscrew the tie rod (3) and the relevant nut (4) so as not to impair the wheel toe-in.

Copyright © SECTION 27 - REAR AXLE Ensure the swivel housing to a lifting device with a rope. Unscrew and remove the screws (5) and (9) from the upper (6) and lower (10) king pins.

Remove the king pins (6) and (10).

Remove the wheel hub assy.

213

Copyright © 214


Assembly of wheel assy and double joint Assemble the wheel hub assy.

Grease the king pin seats (6) and (10). Position the belleville washers on the king pin seats. Assemble the lower (10) and the upper (6) king pins.

Assemble the upper (6) and lower (10) and king pins by fastening the screws (9) and (5) to the prescribed torque of 300 Nm (221 lbf·ft).

Insert the ball joint of the tie rod (3) into its seat on the swivel housing (1) by turning the swivel housing as much as necessary. Do not unscrew the tie rod (3) and the relevant nut (4) so as not to impair the wheel toe-in.

Copyright © SECTION 27 - REAR AXLE Screw in and tighten the nut (2) to a tightening torque of 260 Nm (192 lbf·ft).

Check the differential oil level from the hole of the oil inlet plug (14) and top up if necessary. Screw in and tighten the plug (14) to the tightening torque of 60 Nm (44 lbf·ft).

215

Copyright © 216


Replacement of the seal ring of the double joint Remove the wheel assy and the double joint. Take out the seal ring (11), paying attention not to damage its seat.

Assemble the new seal ring (11) with the buffer 380002226 and a hammer. Lubricate the seal ring.

Check the correct place of the seal ring (11) according to the axle type.

Copyright © SECTION 27 - REAR AXLE Replacement of the bronze bushing of the double joint Remove the wheel assy and the double joint. Extract the seal ring (11). Remove the bronze bushing (13) with a puller, paying attention not to damage its seat.

Insert the new bronze bushing (13) with the buffer 380200227 and a hammer.

Assemble the seal ring (11).

217

Copyright © 218


Brake wear check Actuate the service brake with machine stopped. Unscrew the breather to release the inner pressure. Unscrew and remove the plug (1).

Check the wear condition of the brake disc friction face by trying to insert between the counterdiscs a dowel with 4.08 mm (0.16 in) of diameter. If the dowel cannot be inserted, the brake discs must be replaced because worn out. If the dowel can be inserted, the brake discs must not be replaced.

Screw in the plug (1) with a dynamometric wrench. Carry out the check of the other brake assy.


219


Tyre resistance.

Broken axle shaft.



POSSIBLE CAUSE

ACTION



Axle faulty.




Overload.




Axle beam bent.




Axle faulty.

Inspect and repair.



Overload.




Axle beam bent.




Axle faulty.

Inspect and repair.



Overload.




Axle beam bent.




Axle faulty.

Inspect and repair.



Overload.










Copyright © 220


FAULT Excessive noise.


Friction noise.


POSSIBLE CAUSE

ACTION



Axle faulty.

Inspect and repair.



Overload.












Axle faulty.

Inspect and repair.



Overload.
























Axle faulty.

Inspect and repair.







POSSIBLE CAUSE Excessive gear load compared to the one expected. Gear adjustment wrong (excessive backlash). Pinion nut loose.


Replace bevel gear. Follow carefully recommended adjustment operations of ring gear and pinion backlash and of tooth marks detection. Replace bevel gear.




Replace bevel gear.




ACTION

Crash load.


221






Replace bevel gear.



Machine overloaded.








Copyright © 222



POSSIBLE CAUSE

ACTION






Intense use.

Replace the flange.

Pinion nut loose.




Intense use.





Intense use.









Intense use.

Replace bearing.






Replace bevel gear.




FAULT

POSSIBLE CAUSE

223

ACTION






Noise during travel.


















Restore the level.


Change lubricant.

Axle beam bent.







Replace the pinion.

Damaged ring gear.

Replace bevel gear.




Replace bevel gear.

Worn bearings.



Replace the pinion.

Axle beam bent.



Intermittent noise.

Constant noise.

Copyright © 224



POSSIBLE CAUSE

ACTION










225

REPAIR TIMES The times are referred to average values of maintenance performed by skilled personnel in workshops equipped with all necessary fixtures for a proper execution of the required works. The repair and/or replacement times are indicated in minutes. We assume that the axle has already been removed from the machine. ASSY Flange

Steering cylinder

Reduction gear assy

Wheel hub

Axle shaft

Brake


OPERATION

TIME (minutes)

Replacement of pinion seal ring

30

Rod replacement (x 1)

30

Ball joint replacement (x 1)

15

Tie rod replacement (x 1)

30

Ball joint boot replacement (x 1)

15

Tie rod boot replacement (x 1)

15

Sensor replacement

15

Steering cylinder replacement

120

Steering cylinder overhauling

240

Sensor replacement and adjustment

60

Gear carrier replacement

20

Gear carrier overhaul (3 planetary gears)

35

Gear carrier overhaul (4 planetary gears)

45

Standard wheel hub replacement

30

Seal ring + wheel hub bearing replacement

75

Stud bolt replacement (x 1)

5

Swivel housing overhauling

90

Swivel housing replacement

70

Double joint replacement

30

Double joint overhauling

60

King pin replacement (x 1)

30

King pin bearing replacement (x 1)

45

Ring gear replacement (x 1)

30

Ball joint replacement (x 1)

45

Replacement of the seal rings of the double joint

45

Cardan joint bronze bushing replacement

60


120


30

Disc and counterdisc replacement (for each side)

60

Overhaul / replacement of piston seal rings (for each side)

90

Self-adjust kit replacement (for each side)

60

Overhaul / replacement of piston (for each side)

90

Overhaul / replacement of O-ring (for each side)

30

Replacement of differential assy

150

Differential box bearings

120

Copyright © 226


ASSY Differential

Pinion

OPERATION

TIME (minutes)

Differential replacement

150

Overhaul / replacement of bevel gear, planetary gears, pins

240

Overhauling / replacement of differential box bearings

120

Overhauling / replacement of pinion bearings

180

Overhaul / replacement of bevel gear, planetary gears, pins

240


227


DESCRIPTION

USE

380002211

Handle


380000021

Wrench


380200188

Buffer


380200190

Buffer

Assembly of pinion bearing cups

380000020

Wrench


380200192

Buffer

Assembly / disassembly of bushings in the ring gear carrier hub

380200194

Buffer


380200195

Buffer

Ball bearing assembly of the lower king pin

380200196

Buffer

Ball bearing assembly of the upper king pin

380000024

Buffer

Bushing assembly into the swivel housing

380200202

False pinion


380200205

Buffer

Assembly of bushings into the differential box

380200209

Wrench

Tighten / loosen the brake cylinder ring nut

380200210

Buffer

Wheel hub seal ring assembly

380200211

Buffer

Assembly of bearing cups into the wheel hub

380200216

Kit

Assembly of pinion bearing cups

380200217



380200218

Buffer

Assembly of bearing cup into the brake cylinder

380200222

Tool

Backlash measure between pinion and ring gear

380200227

Buffer

Assembly of bushing in the half-beam

380002226

Buffer

Assembly of seal ring in the half-beam

380200237

Tool

Preload measure

380200238

Buffer

Brake piston assembly

380200266

Buffer

Seal ring assembly into the swivel housing

380200267

Buffer


Copyright © 228

NOTES:


Copyright ©

580T 580ST 590ST 695ST

SECTION 33 - BRAKE SYSTEM PARKING BRAKE............................................................................................................................................. 3 TECHNICAL SPECIFICATIONS.................................................................................................................. 3 OPERATION................................................................................................................................................ 3 ADJUSTMENT............................................................................................................................................. 4 DISASSEMBLY AND ASSEMBLY............................................................................................................... 5 SERVICE BRAKE ........................................................................................................................................... 14 TECHNICAL SPECIFICATIONS................................................................................................................ 14 OPERATION.............................................................................................................................................. 14

Copyright © 2

SECTION 33 - BRAKE SYSTEM

Copyright © SECTION 33 - BRAKE SYSTEM

3

PARKING BRAKE This device allows the immobilization of the machine each time it must be parked or stopped to carry out maintenance work.

TECHNICAL SPECIFICATIONS Type ....................................................................................................................................... manual, with lever Maximum lever pull ....................................................................................................................1650 N (371 lbf) Lever stroke ............................................................................................................................... 21 mm (0.87 in) Maximum torque - Powershuttle ..........................................................................................2000 Nm (450 lbf·ft) Maximum torque - Powershift ..............................................................................................1500 Nm (337 lbf·ft)

OPERATION The parking brake essentially consists of: - manual control lever; - transmission brake.

The lever (1) is located on the right side of the cab (seat placed to loader attachment). The lever position (1) is controlled by the sensor (2), when the lever is lifted to immobilize the machine, the lamp (3) indicating the parking brake activation and placed on the side instrument panel (4), lights on. IMPORTANT: if the gear is engaged when the parking brake is activated, it will actuate the warning buzzer and the symbol “parking brake alarm” will appear on the display. By lifting the lever (1), by means of cable (5) and of the relevant yoke (7), the brake is actuated inside transmission (6).

Copyright © 4


NEGATIVE PARKING BRAKE OPERATION Negative parking brake applied (A) When the system is not under pressure, the belleville washers (1) push on the parking brake piston (2) compressing the brake discs (3). This happens when the machine motor is stopped or because the operator has actuated the parking brake. In order to move the machine disable the parking brake.

Negative brake released (B) When the brake oil reaches the disengagement pressure, the parking brake piston (2) is pushed against the belleville washers (1) and the brake discs (3) are free. This happens under normal operating condition, when the operator disengages the parking brake.

ADJUSTMENT The parking brake can be adjusted by placing the brake pad in contact with the disc, now you have to block the brake cable. The brake cable movement (1) can be adjusted by handling on the locknut (2). Adjust the parking brake so as to brake the machine completely by lifting the brake lever up to the 4th ratchet.

Copyright © SECTION 33 - BRAKE SYSTEM DISASSEMBLY AND ASSEMBLY These procedures deal with the parking brake section and leave off the control lever and the relevant connection cable.

1. Screw

10. Piston

2. Washer

11. Snap ring

3. O-ring

12. O-ring

4. Flange

13. Stop plate

5. Screw

14. O-ring

6. Brake cover

15. Disc

7. O-ring

16. Brake discs

8. Belleville washer

17. Hub

9. O-ring

5

Copyright © 6


DISASSEMBLY Loosen the screw (1).

Remove the screw (1) and the washer (2).

Remove the O-ring (3) and the flange (4).

Loosen the screws (5).

Copyright © SECTION 33 - BRAKE SYSTEM Remove all screws (5), the screws (A) and alternately loosen the screws (B) to release the load from the belleville washers. NOTE: the housing is under spring pressure, failure to follow the instructions will result in serious injury or damage to the equipment.

Remove the brake cover (6). Remove the O-ring (7).

Remove the brake discs (16).

Remove the hub (17).

7

Copyright © 8


Remove the retaining plate (13).

Remove the O-rings (12) and (14) from the retaining plate.

Compress the belleville washers, to remove the snap ring (11).

Remove the piston (10) from the brake cover (6).

Copyright © SECTION 33 - BRAKE SYSTEM Remove the O-ring (9) from the piston (10).

Remove the belleville washers (8) from the brake cover (6).

INSPECTION Clean all parts in cleaning solvent. Inspect the brake discs and plates for pitting, scoring, excessive surface wear and other damage. Inspect the belleville washer for cracking and excessive surface wear at contact points. Inspect brake pistons and housing for scratches on their sliding surfaces, and contact surfaces for pitting or excessive wear. Replace the O-rings.

9

Copyright © 10


ASSEMBLY Assemble the new O-ring (7) on the brake cover (6).

Assemble the belleville washers (8).

Assemble the new O-ring (9) on the piston (10).

Lubricate and install the piston (10) into the brake cover (6).

Copyright © SECTION 33 - BRAKE SYSTEM Compress the belleville washers, to assemble the snap ring (11).

Assemble new O-rings (12) and (14) onto the retaining plate.

Lubricate and install the retaining plate (13) into the brake cover (6).

Assemble the hub (17).

11

Copyright © 12


Assemble the brake discs (16).

Assemble the brake cover assembly.


Assemble the flange (4) and the new O-ring (3).

Copyright © SECTION 33 - BRAKE SYSTEM Screw in the screw (1) with the washer (2).

Tighten the screw (1) to a tightening torque of 139 Nm (102 lbf·ft).

13

Copyright © 14


SERVICE BRAKE During operation, the brake system of the machine can stop the machine at any time.

TECHNICAL SPECIFICATIONS 2WS Type ........................................................................................................wet multi-discs, 4 x axle (2 x half axle) Braking surface ..................................................................................................................... 1236 cm2 (191 in2) 4WS Type ........................................................................................................wet multi-discs, 6 x axle (3 x half axle) Braking surface ..................................................................................................................... 1092 cm2 (169 in2)

OPERATION This system essentially consists of: - brake pedals (in the cab); - wet disc brakes hydraulically operated in the rear axle.

NOTE: this drawing represents the 2WS rear axle; the operation of the 4WS rear axle is the same. The two pedals (1) located in the cab underneath the steering wheel, can be matched with the locking pin (2). This enables: - the machine braking (pedals locked together); - the machine turning (by pushing just one pedal).

By pushing the pedals (1) you activate the brake pump (3) delivering hydraulic oil to the 2 brake discs (5) fitted in the rear axle (6). In this way, pressure is generated against the brake pistons (7), which, on their turn, compress the discs (9) and the counterdiscs (8), thus locking the axle and therefore the machine.

Copyright ©

580T 580ST 590ST 695ST

SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC DIAGRAMS ................................................................................................................................. 3 HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS....................................................... 3 HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS .................................................................... 9 HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS..................................................... 13 HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS .................................................................. 15 HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS .......................................................... 17 HYDRAULIC PUMP........................................................................................................................................ 19 HYDRAULIC FIXED-FLOW-RATE GEAR PUMP...................................................................................... 19 HYDRAULIC VARIABLE-FLOW-RATE PISTON PUMP ........................................................................... 30 CONTROL VALVES ....................................................................................................................................... 44 LOADER CONTROL VALVE ..................................................................................................................... 53 BACKHOE ATTACHMENT CONTROL VALVE......................................................................................... 57 RELIEF VALVES ....................................................................................................................................... 69 BACKHOE ATTACHMENT CONTROL VALVE PILOT SOLENOID VALVE .................................................. 78 ACCUMULATOR “GLIDE RIDE” PARKER..................................................................................................... 81 TECHNICAL SPECIFICATIONS................................................................................................................ 81 MAINTENANCE......................................................................................................................................... 81 SAFETY ..................................................................................................................................................... 81 CHECKING AND ADJUSTING THE PRECHARGE PRESSURE ............................................................. 82 HYDRAULIC SWING SYSTEM ...................................................................................................................... 84 OPERATION.............................................................................................................................................. 84 HYDRAULIC CYLINDERS.............................................................................................................................. 87 LOADER ATTACHMENT BOOM CYLINDER ........................................................................................... 88 LOADER BUCKET CYLINDER ................................................................................................................. 93 4X1 LOADER BUCKET CYLINDER .......................................................................................................... 97 BACKHOE BOOM CYLINDER ................................................................................................................ 100 BACKHOE ATTACHMENT DIPPER CYLINDER .................................................................................... 104

Copyright © 2

SECTION 35 - HYDRAULIC SYSTEM BACKHOE BUCKET CYLINDER............................................................................................................. 108 TELESCOPIC CYLINDER ....................................................................................................................... 112 STABILIZER CYLINDER - CENTER PIVOT (695ST).............................................................................. 115 STABILIZER CYLINDER - SIDESHIFT ................................................................................................... 119 SWING CYLINDER.................................................................................................................................. 123 BACKHOE ATTACHMENT LOCK CYLINDER - SIDESHIFT .................................................................. 127 SPECIAL TOOLS..................................................................................................................................... 128

HYDRAULIC CONTROL LEVERS................................................................................................................ 129 TECHNICAL SPECIFICATIONS.............................................................................................................. 129 CONTROLS AND OPERATION .............................................................................................................. 130 COMPONENTS ....................................................................................................................................... 131 DISASSEMBLY AND ASSEMBLY........................................................................................................... 133 CONTROL LEVER VALVE ...................................................................................................................... 136 TROUBLESHOOTING .................................................................................................................................. 138 PRELIMINARY CHECKS......................................................................................................................... 138 TROUBLESHOOTING (WITH “REXROTH” CONTROL VALVES).......................................................... 139 SWING ..................................................................................................................................................... 141 HYDRAULIC PUMP ................................................................................................................................. 142

Copyright © SECTION 35 - HYDRAULIC SYSTEM

HYDRAULIC DIAGRAMS HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS WITH FIXED-FLOW-RATE GEAR PUMP

* Alternative diagram for non-reactive steering

3

Copyright © 4

SECTION 35 - HYDRAULIC SYSTEM

1.

Front axle steering cylinder

2.

Power steering

3.

4x1 bucket cylinders

3A. Lock valve 4.

Dipper cylinders

4A. Lock valve 5.

Boom cylinders

5A. Lock valve 6.

Ride control valve (optional)

7.

Ride control accumulator (optional)

8.

Loader attachment control valve

9.

Hand hammer control valve (optional)

10. Backhoe hammer control valve (optional) 11. Hand hammer (optional) 12. Backhoe hammer (optional) 13. Hydraulic fixed-flow-rate gear pump 14. Priority valve 15. Oil cooler 16. Hydraulic tank 17. Air filter 18. Oil filter 19. Backpressure valve 20. Return filter 21. Backhoe attachment travel lock cylinders (sideshift) 22. Stabilizer right cylinder 22A.Lock valve 23. Stabilizer left cylinder 23A.Lock valve 24. Dipper cylinder 24A.Lock valve 25. Bucket cylinder 26. Swing cylinders 27. Swing control valve 28. Boom cylinder 28A.Lock valve 29. Telescopic cylinder 30. Backhoe attachment control valve 31. Backhoe quick coupler (optional) 32. Backhoe quick coupler control valve (optional) 33. Diagnostic

Copyright © SECTION 35 - HYDRAULIC SYSTEM WITH FIXED-FLOW-RATE GEAR PUMP - WITHOUT BACKHOE ATTACHMENT SWING CONTROL VALVE

5

Copyright © 6


1.


2.

Power steering

3.


3A. Lock valve 4.

Dipper cylinders

4A. Lock valve 5.

Boom cylinders

5A. Lock valve 6.


7.


8.


9.


10. Backhoe hammer control valve (optional) 11. Hand hammer (optional) 12. Backhoe hammer (optional) 13. Hydraulic fixed-flow-rate gear pump 14. Priority valve 15. Oil cooler 16. Hydraulic tank 17. Air filter 18. Oil filter 19. Backpressure valve 20. Return filter 21. Backhoe attachment travel lock cylinders (sideshift) 22. Stabilizer right cylinder 22A.Lock valve 23. Stabilizer left cylinder 23A.Lock valve 24. Dipper cylinder 24A.Lock valve 25. Bucket cylinder 26. Swing cylinders 27. Diagnostic 28. Boom cylinder 28A.Lock valve 29. Telescopic cylinder 30. Backhoe attachment control valve 31. Backhoe quick coupler (optional) 32. Backhoe quick coupler control valve (optional)

Copyright © SECTION 35 - HYDRAULIC SYSTEM WITH VARIABLE-FLOW-RATE PISTON PUMP


7

Copyright © 8


1.


2.

Power steering

3.


3A. Lock valve 4.

Dipper cylinders

4A. Lock valve 5.

Boom cylinders

5A. Lock valve 6.


7.


8.


9.


10. Backhoe hammer control valve (optional) 11. Hand hammer (optional) 12. Backhoe hammer (optional) 13. Hydraulic variable-flow-rate piston pump 14. Priority valve 15. Oil cooler 16. Hydraulic tank 17. Air filter 18. Oil filter 19. Backpressure valve 20. Return filter 21. Backhoe attachment travel lock cylinders (sideshift) 22. Stabilizer right cylinder 22A.Lock valve 23. Stabilizer left cylinder 23A.Lock valve 24. Dipper cylinder 24A.Lock valve 25. Bucket cylinder 26. Swing cylinders 27. Diagnostic 28. Boom cylinder 28A.Lock valve 29. Telescopic cylinder 30. Backhoe attachment control valve 31. Bidirectional auxiliary attachment (optional) 32. Backhoe quick coupler (optional) 33. Backhoe quick coupler control valve (optional)

Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS WITH FIXED-FLOW-RATE GEAR PUMP


9

Copyright © 10


1. Front axle steering cylinder 2. Power steering 3. 4x1 bucket cylinders 3A. Lock valve 4. Dipper cylinders 4A. Lock valve 5. Boom cylinders 5A. Lock valve 6. Ride control valve (optional) 7. Ride control accumulator (optional) 8. Loader attachment control valve 9. Hand hammer control valve (optional) 10. Backhoe hammer control valve (optional) 11. Hand hammer (optional) 12. Backhoe hammer (optional) 13. Hydraulic fixed-flow-rate piston pump 14. Priority valve 15. Oil cooler 16. Hydraulic tank 17. Air filter 18. Oil filter 19. Backpressure valve 20. Return filter 21. Backhoe attachment travel lock cylinders (sideshift) 22. Stabilizer right cylinder 22A.Lock valve 23. Stabilizer left cylinder 23A.Lock valve 24. Dipper cylinder 24A.Lock valve 25. Bucket cylinder 26. Swing cylinders 27. Swing control valve 28. Boom cylinder 28A.Lock valve 29. Telescopic cylinder 30. Backhoe attachment control valve 31. Bidirectional auxiliary attachment (optional) 32. Backhoe quick coupler (optional) 33. Backhoe quick coupler control valve (optional) 34. Diagnostic 35. Left-hand hydraulic control lever 35A.Left hydraulic control lever - boom - dipper 35B.Left hydraulic control lever - swing 36. Right-hand hydraulic control lever 36A.Right hydraulic control lever - boom - dipper 36B.Right hydraulic control lever - swing 37. Backhoe attachment control valve solenoid valve

Copyright © SECTION 35 - HYDRAULIC SYSTEM WITH VARIABLE-FLOW-RATE PISTON PUMP


11

Copyright © 12


1. Front axle steering cylinder 2. Power steering 3. 4x1 bucket cylinders 3A. Lock valve 4. Dipper cylinders 4A. Lock valve 5. Boom cylinders 5A. Lock valve 6. Ride control valve (optional) 7. Ride control accumulator (optional) 8. Loader attachment control valve 9. Hand hammer control valve (optional) 10. Backhoe hammer control valve (optional) 11. Hand hammer (optional) 12. Backhoe hammer (optional) 13. Hydraulic variable-flow-rate piston pump 14. Priority valve 15. Oil cooler 16. Hydraulic tank 17. Air filter 18. Oil filter 19. Backpressure valve 20. Return filter 21. Backhoe attachment travel lock cylinders (sideshift) 22. Stabilizer right cylinder 22A.Lock valve 23. Stabilizer left cylinder 23A.Lock valve 24. Dipper cylinder 24A.Lock valve 25. Bucket cylinder 26. Swing cylinders 27. Swing control valve 28. Boom cylinder 28A.Lock valve 29. Telescopic cylinder 30. Backhoe attachment control valve 31. Bidirectional auxiliary attachment (optional) 32. Backhoe quick coupler (optional) 33. Backhoe quick coupler control valve (optional) 34. Backhoe attachment control valve solenoid valve 35. Left-hand hydraulic control lever 35A.Left hydraulic control lever - boom - dipper 35B.Left hydraulic control lever - swing 36. Right-hand hydraulic control lever 36A.Right hydraulic control lever - boom - dipper 36B.Right hydraulic control lever - swing

Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS

13

Copyright © 14 1.

SECTION 35 - HYDRAULIC SYSTEM Front axle steering cylinder

2.

Rear axle steering cylinder

3.

4WS steering control valve

4.

Power steering

5.


5A. Lock valve 6.

Dipper cylinders

6A. Lock valve 7.

Boom cylinders

7A. Lock valve 8.


9.


10. Loader attachment control valve 11. Hand hammer control valve (optional) 12. Backhoe hammer control valve (optional) 13. Hand hammer (optional) 14. Backhoe hammer (optional) 15. Hydraulic variable-flow-rate pump 16. Priority valve 17. Oil cooler 18. Hydraulic tank 19. Air filter 20. Oil filter 21. Return filter 22. Backpressure valve 23. Backhoe attachment control valve 24. Backhoe attachment travel lock cylinders (sideshift) 25. Bidirectional auxiliary attachment (optional) 26. Stabilizer right cylinder 26A.Lock valve 27. Stabilizer left cylinder 27A.Lock valve 28. Dipper cylinder 28A.Lock valve 29. Bucket cylinder 30. Swing cylinders 31. Swing control valve 32. Boom cylinder 32A.Lock valve 33. Telescopic dipper cylinder (optional) 34. Backhoe quick coupler (optional) 35. Backhoe quick coupler control valve (optional)

Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS

15

Copyright © 16 1.


2. 4WS steering control valve 3. Rear axle steering cylinder 4. Power steering 5. 4x1 bucket cylinders 5A. Lock valve 6. Dipper cylinders 6A. Lock valve 7. Boom cylinders 7A. Lock valve 8. Ride control valve (optional) 9. Ride control accumulator (optional) 10. Loader attachment control valve 11. Hand hammer control valve (optional) 12. Backhoe hammer control valve (optional) 13. Hand hammer (optional) 14. Backhoe hammer (optional) 15. Hydraulic variable-flow-rate piston pump 16. Priority valve 17. Oil cooler 18. Hydraulic tank 19. Air filter 20. Oil filter 21. Return filter 22. Backpressure valve 23. Backhoe attachment control valve 24. Bidirectional auxiliary attachment (optional) 25. Stabilizer right cylinder 25A.Lock valve 26. Stabilizer left cylinder 26A.Lock valve 27. Dipper cylinder 27A.Lock valve 28. Bucket cylinder 29. Swing cylinders 30. Swing control valve 31. Boom cylinder 31A.Lock valve 32. Telescopic dipper cylinder (optional) 33. Backhoe quick coupler (optional) 34. Backhoe quick coupler control valve (optional) 35. Left-hand hydraulic control lever 35A.Boom or dipper left hydraulic control lever 35B.Left hydraulic control lever - swing 36. Right-hand hydraulic control lever 36A.Boom or dipper right hydraulic control lever 36B.Hydraulic control lever right-bucket 37. Backhoe attachment control valve solenoid valve

Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS

17

Copyright © 18 1.


2. 4WS steering control valve 3. Rear axle steering cylinder 4. Power steering 5. 4x1 bucket cylinders 5A. Lock valve 6. Dipper cylinders 6A. Lock valve 7. Boom cylinders 7A. Lock valve 8. Ride control valve (optional) 9. Ride control accumulator (optional) 10. Loader attachment control valve 11. Hand hammer control valve (optional) 12. Backhoe hammer control valve (optional) 13. Hand hammer (optional) 14. Backhoe hammer (optional) 15. Hydraulic variable-flow-rate piston pump 16. Priority valve 17. Oil cooler 18. Hydraulic tank 19. Air filter 20. Oil filter 21. Return filter 22. Backpressure valve 23. Backhoe attachment control valve 24. Bidirectional auxiliary attachment (optional) 25. Stabilizer right cylinder 25A.Lock valve 26. Stabilizer left cylinder 26A.Lock valve 27. Dipper cylinder 27A.Lock valve 28. Bucket cylinder 29. Swing cylinders 30. Swing control valve 31. Boom cylinder 31A.Lock valve 32. Telescopic cylinder 33. Backhoe quick coupler (optional) 34. Backhoe quick coupler control valve (optional) 35. Left-hand hydraulic control lever 35A.Boom or dipper left hydraulic control lever 35B.Left hydraulic control lever - swing 36. Right-hand hydraulic control lever 36A.Boom or dipper right hydraulic control lever 36B.Hydraulic control lever right-bucket 37. Backhoe attachment control valve solenoid valve


19

HYDRAULIC PUMP The machine can be provided with 2 types of hydraulic pump: - fixed-flow-rate gear pump; - variable-flow-rate piston pump. Further to the type, pumps differentiate according to the motor: - 72 kW (97 HP) motor; - 82 kW (110 HP) motor.

HYDRAULIC FIXED-FLOW-RATE GEAR PUMP The hydraulic pump is mounted on the rear part of the transmission and is driven by a shaft directly connected to the engine splined to the torque converter. The pump consists of two pumping elements, the front pump (1) and the rear pump (2), and a loadsensing flow divider valve (3) for the steering system. Oil is drawn through the common inlet port into both pumping elements. The front pump flow is directed to the loader and backhoe attachment control valve and also to the sideshift carriage lock cylinders. The rear pump flow passes through the flow divider valve, which maintains priority oil flow to the steering system, with the remaining flow directed for operating the stabilizers.

TECHNICAL SPECIFICATIONS Pump 72 kW - 97 HP (580T - 580ST) Model .......................................................................................................... CASAPPA KP 30.34 - 05 S6 - LMF Type ...................................................................................................................................... double gear pump Displacement ............................................................................. 35.427 + 35.427 cm3/rev (2.16 + 2.16 in3/rev) Pump 82 kW - 110 HP (590ST - 695ST) Model .......................................................................................................... CASAPPA KP 30.38 - 05 S6 - LMF Type ...................................................................................................................................... double gear pump Displacement ............................................................................. 40.258 + 35.427 cm3/rev (2.45 + 2.16 in3/rev)

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PUMP (97 HP ENGINE)

1st PUMP

Direction of rotation (looking on drive shaft)

2nd PUMP

Clockwise (D) 35.427 cm3/rev (2.16 in3/rev)

Displacement Inlet pressure range for pump

35.427 cm3/rev (2.16 in3/rev)

0.7 - 3 bar (10 - 43 psi)

Maximum continuous pressure

P1

260 bar (3771 psi)

260 bar (3771 psi)

Maximum intermittent pressure

P2

280 bar (4061 psi)

280 bar (4061 psi)

Maximum peak pressure

P3

300 bar (4351 psi)

300 bar (4351 psi)

Operating temperature

-25 to -80 °C (-13 to -112 °F) min P1

Speed

350 rpm

max P1

Viscosity range

Contamination class

3000 rpm 2

recommended

12 to 100 mm /s (0.47 to 3.93 in/s²) (cSt)

permitted

max 750 mm2/s (29.53 in/s²) (cSt)

Dp > 200 bar (2900 psi) bx = 75 - 10 mm (3.0 - 0.39 in)

8 - Nas 1638

Dp < 200 bar (2900 psi) bx = 75 - 25 mm (3.0 - 0.98 in)

Relief valve

19 / 17 /14 - ISO 4406 10 - Nas 1638 21 / 19 /16 - ISO 4406 177 ± 3 bar (2567 - 43 psi)

Stand by pressure load sensing valve

7 bar (102 psi)

Weight

30 kg (66 lb)

PUMP (110 HP ENGINE)

1st PUMP

Direction of rotation (looking on drive shaft)

2nd PUMP

Clockwise (D) 40.258 cm3/rev (2.45 in3/rev)

Displacement Inlet pressure range for pump

35.427 cm3/rev (2.16 in3/rev)

0.7 - 3 bar (10 - 43 psi)

Maximum continuous pressure

P1

260 bar (3771 psi)

260 bar (3771 psi)

Maximum intermittent pressure

P2

280 bar (4061 psi)

280 bar (4061 psi)

Maximum peak pressure

P3

300 bar (4351 psi)

300 bar (4351 psi)

Operating temperature Speed Viscosity range

Contamination class

Relief valve Stand by pressure load sensing valve Weight

-25 to -80 °C (-13 to -112 °F) min P1

350 rpm

max P1

3000 rpm

recommended

12 to 100 mm2/s (0.47 to 3.93 in/s²) (cSt)

permitted

max 750 mm2/s (29.53 in/s²) (cSt)

Dp > 200 bar (2900 psi) bx = 75 - 10 mm (3.0 - 0.39 in)

8 - Nas 1638 19 / 17 /14 - ISO 4406

Dp < 200 bar (2900 psi) bx = 75 - 25 mm (3.0 - 0.98 in)

21 / 19 /16 - ISO 4406

10 - Nas 1638 177 ± 3 bar (2567 - 43 psi) 7 bar (102 psi) 30 kg (66 lb)

Copyright © SECTION 35 - HYDRAULIC SYSTEM Tightening torques

Hydraulic diagram

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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. Lock plug

6. Orifice

13. Load sensing signal (LS)

7. Inlet port from rear pump (IN)

14. Orifice

When the steering is in neutral the LS port is connected to the unload (through the steering) and the steering inlet port (CF) is open.


23

Load sensing valve with pump running - Steering in neutral

1. 2. 3. 4.

Return to oil tank Trapped oil Pressure oil Orifice Rear systems (EF) Filter Spool

5. To steering priority flow (CF) 6. Orifice 7. Inlet port (from rear port)

The pressure on (CF) increases until the pressure value (stand-by pressure) is sufficient to move the spool valve in a way to divert the flow toward (EF).

Load sensing valve with pump running - Steering working

1. 2. 3. 4.

Trapped oil Return to oil tank Orifice Rear systems (EF) Filter Spool

During steering two actions are performed: 1. The fluid moves to the steering through (CF). 2. The (LS) signal is in communication to the steering.

5. To steering priority flow (CF) 6. Orifice 7. Inlet port (from rear port)

Copyright © 24


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. Fitting

26. Front pump body

9. Spring seat

27. Gasket

10. Spring

28. Gear

11. O-ring

29. Flange

12. Cover

30. Seal ring

13. Relief valve

31. Seal ring

14. O-ring

32. Snap ring

15. Poppet

33. Pressure seal

16. Spring

34. Gear

17. Seat

35. O-ring

18. Rear pump body

36. Screw

Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY AND ASSEMBLY Disassembly of the steering control valve To aid reassembly draw an alignment line along the total length of the pump assembly. Remove the screws (1).

Remove the load-sensing steering control valve (2). Check and replace the O-rings (35), if necessary.

Disassembly of the steering control valve Do not disassemble the steering system relief valve (A) if the valve’s pressure is to specification when pressure-testing the pump prior to overhaul. NOTE: if the steering system pressure relief valve is disassembled, the valve must be reset as described in Chapter “Troubleshooting, pressure and flow testing”. Wash all components in an approved degreaser and check the following: - the valve bore must be free from scoring or damage to metering edges; - the spool (3) should slide freely in the bore and must be free from scoring or damage; - ensure all orifices are clean; - the valve seat must not show cavities or damage (a small chamfer at the entrance of the bore is allowed); - examine the filter (7) mounted inside the outlet and relief valves and replace the filter if dirty. Pressure and flow test the pump.

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Rear pump disassembly 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. Write an identifying letter “A” and “B”, “C” and “D” on the pump housing and in the channel of each bearing block. NOTE: orientation of bearing block seals relative to oil port. If scribe is not available take care to keep bearing blocks in pairs.

Disassemble the gears (24), the seals (33), the elastic retainers (22) and the bearings (23). Wash all components in approved degreaser.

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 (0.0031 ÷ 0.0029 in) in depth. Examine bearing block faces for scoring and flatness, paying particular attention to the face which abuts the gears. Examine bearing block bushes for scoring. Examine pump gears for scored or worn side faces, journals and damaged teeth. If pump block, gears or bearing blocks are worn and require replacement the pump assembly must be replaced. Re-assemble using the disassembly procedure in reverse order and observe the following warnings: - ensure that all parts are perfectly clean and lubricate bushes and gears with clean hydraulic fluid; - replace all seals and O-rings; - install the bearing blocks into the same positions from which they were removed, using the identification letters written during disassembly; - ensure plastic back-up seals are correctly positioned in the rubber seal.

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Front pump disassembly To remove the pump assy (26) from the flange (29) it is necessary to remove the snap ring (33). Remove and replace the seal rings (30) and (31).

Identify and note the position of each bearing block to ensure correct reassembly. Disassemble the gears (28) and (34), the seals (33), the elastic retainers and the bearings (23). Wash all components in approved degreaser.

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 (0.006 in) in depth. Examine bearing block faces for scoring. Inspect teflon coated bearings in body or flange for wear. If bearings are worn the bronze backing will be revealed. Examine pump gears for scored or worn side faces, journals and damaged teeth. Examine flange seal contact area on driveshaft. If pump block, gears, bearing blocks or drive shaft are worn the pump assembly must be replaced. Re-assemble using the disassembly procedure in reverse order and observe the following warnings: - ensure that all parts are perfectly clean and lubricate bushes and gears with clean hydraulic oil; - replace all seals and O-rings; - install bearing blocks into the same positions from which they were removed; - make sure the safety retainers are correctly positioned in the rubber seal rings.

Copyright © SECTION 35 - HYDRAULIC SYSTEM Assemble the inner seal, (30), with the spring and the lip facing the pump. Install the outer seal ring (31), with the spring and the lip facing outwards and refit the snap ring (30). Coat the rings with high melting point grease. NOTE: ensure seal rings are fitted back to back. NOTE: if the seal ring recess has been scored during seal removal, coat the outside diameter of the seal ring with flexible gasket sealant to prevent leakage.

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HYDRAULIC VARIABLE-FLOW-RATE PISTON PUMP As an alternative to the fixed-flow-rate gear pump, the machine can be provided with another type of variable-flow-rate pump. TECHNICAL SPECIFICATIONS Pump 72 kW - 97 HP (580ST) Model ....................................................................................................................... DANFOSS J71C Series 45 Type ......................................................................................................................................... with axial pistons Displacement ............................................................................................................... 71 cm3/rev (4.33 in3/rev) Pump 82 kW - 110 HP (590ST - 695ST) Model ....................................................................................................................... DANFOSS J75C Series 45 Type ......................................................................................................................................... with axial pistons Displacement ............................................................................................................... 75 cm3/rev (4.57 in3/rev)

Copyright © SECTION 35 - HYDRAULIC SYSTEM COMPONENTS

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Copyright © 32


1. Snap ring

32. Piston disc

2. Seal ring

33. Articulation

3. Pump body

34. Pin

4. O-ring

35. Cylinder

5. Plug

36. Washer

6. Plug

37. Spring

7. O-ring

38. Washer

8. Bearing

39. Ring

9. Shaft

40. Plug

10. Cradle bearing

41. O-ring

11. Pin

42. Spool

12. Snap ring

43. Plug

13. Pin

44. O-ring

14. Swash plate

45. Spool

15. Spring

46. Valve body

16. Piston

47. O-ring

17. Cylinder assy

48. Plug

18. O-ring

49. Spring guide

19. Bearing

50. Spring

20. Pin

51. Spring

21. Valve plate

52. O-ring

22. Check valve

53. Adjusting screw

23. Spring

54. Plug

24. O-ring

55. O-ring

25. Plug

56. Spring guide

26. Cover

57. Spring

27. Screw

58. Spring

28. O-ring

59. Back-up ring

29. Load-sensing control valve

60. O-ring

30. Screw

61. Adjusting screw

31. Piston

62. Dowel

Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY AND ASSEMBLY Disassembly Remove the load-sensing control valve (29) by removing the 4 screws (30). Remove and discard the 4 O-rings (28).

Loosen and remove the 4 screws (27). Carefully remove the end cap (26). Prevent the valve plate (21) from falling off. Place the end cap and valve plate in a clean area, protecting them from contamination. Remove the bearing (19) and the O-ring (18).

Tilt the pump body to allow oil to drain. Remove the cylinder assy (17). Set the cylinder assy on a clean and dry surface.

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Copyright © 34


Rotate the pump body (3) to a position so that the shaft is pointing down. Pull the shaft (9) out of the pump body (3). Compress the spring (15) and rotate the piston (16) towards the swash plate (14). Lift the swash plate/piston assy until it is tilted and remove it from the pump body (3). Remove the piston (16) and the spring (15) from the swash plate (17) by removing the pin (13) and the snap ring (12).

Remove the bearing (8). Examine the cradle bearings (10) to determine if they need replacement. Removing the pins (11) will likely damage the cradle bearings, so make sure you have replacement bearings before you remove them. If cradle bearings (10) need replacing, remove the 2 pins (11). Note the location and orientation of the bearings for re-installation.

Copyright © SECTION 35 - HYDRAULIC SYSTEM Orient the pump body (3) with the flange upwards. Remove the snap ring (1). Carefully pry out the seal ring (2). In case it is not possible to extract the seal ring (2), try to push the seal out by going through the inside of the pump body (3).

Disassembly of the load-sensing control valve (29) Remove the 4 plugs (40), (43), (48), (54) and their O-rings (41), (44), (47), (55). Remove the 2 screws (62). Remove the spools (42), (45). Note which bore each spool came out of. Also note the orientation of each spool for reinsertion. There may be differences in reinserting into the same bore. Remove the adjusting screw (53) and the O-ring (52). Remove the springs (51), (50) and the spring guide (49). Remove the adjusting screw (61), the O-ring (60) and the back-up ring (59). Remove the springs (57), (58) and the spring guide (56).

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Copyright © 36


Disassembly of cylinder assy (17) Pull to extract the piston disc (32) with the pistons (31) from the cylinder (35). Number the pistons and bores for reassembly if they are to be reused. Remove the articulation (33). Remove the 3 pins (34). NOTE: perform this procedure only if you suspect problems with the spring. Turn the cylinder (35) over. Using a press, apply pressure on the washer (38) to compress the spring (37). Compress the spring enough to safely remove the ring (39). Carefully release the pressure and remove the washer (38), the spring (37) and the washer (36) from the cylinder (35).

WARNING Compressing the spring (37) requires about 350 ÷ 400 N (79 ÷ 90 lbf). Use a press sufficient to maintain this force. Ensure that the spring is secure before attempting to remove the ring (39). Release the pressure slowly after the ring (39) has been removed.

Copyright © SECTION 35 - HYDRAULIC SYSTEM Inspection After disassembly, wash all parts (including the end cap and the pump body) thoroughly with clean solvent and allow to air dry. Clean the oil ducts in the pump body and the end cover with compressed air. Conduct inspection in a clean area and keep all parts free from contamination. Inspect the pistons (31) for damage and discoloration. Discoloured pistons may indicate excessive heat; do not reuse. Inspect the running surface of the pistons (A). Replace all pistons with scored or excessively rounded edges. Measure the piston foot thickness (B). Replace all excessively worn pistons. Check the axial end-play (C). Replace all pistons with excessive end-play. Foot thickness (B)

3.23 mm (0.13 in)

Piston axial end-play (C)

0.05 mm (0.002 in)

The articulation (33) should be free of nicks and scratches, and should not be excessively scored. Examine for discoloration that may indicate excessive heat or lack of lubrication. The piston disc (32) must be flat. The pistons must insert with a minimum side play. Place the pins (34) on a flat surface and roll them to make sure they are straight. Discard and replace any damaged parts.

If the cylinder assy was fully dissembled, visual inspection of the cylinder block, spring (37) and washers (36), (38) should indicate minimal wear. Replace if cracks or other damage is present.

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Examine the running face of the cylinder (35). The surface should be smooth and free of nicks and burrs. Ensure that no scratches or grooves exist; these may drastically reduce output flow. Minimum height (D)

62.25 mm (2.45 in)

Maximum bore diameter (E)

19.8 mm (0.78 in)

Inspection of the load-sensing control valve (29). Carefully examine the plugs (40), (43), (48), (54) for signs of wear. Inspect all springs to make sure they are intact. Check the inside and outside surfaces of the springs for wear. Check the spool’s (42), (45) outside diameter for scratches and/or burrs. Clean and coat all spools, bores and seals with a light coating of oil.

Make sure that the shaft (9) and its splines are straight and free of damage or heavy wear. Inspect the shaft surface where it meets the seal ring. Replace the shaft if a groove exists at the sealing land surface that may let dirt into or hydraulic oil out of the unit. Clean the sealing area with non-abrasive material. Lubricate the shaft with a light coat of oil.

Copyright © SECTION 35 - HYDRAULIC SYSTEM Carefully inspect each surface of the swash plate (14) for wear. All swash plate surfaces should be smooth. Inspect the swash plate’s running surface for damage and brass transfer. Excessive transfer may indicate that the pistons should be replaced. Finally, check the swash plate pin for scratches.

Inspect the cradle bearings (10) for damage or excessive wear. The polymer wear layer must be smooth and intact. Replace if scratched or excessively worn. Inspect the valve plate (21) for scratches or grooves. Check the plate for evidence of any cavitation along the running face. If pitting from cavitation exists, replace the valve plate. Check for excess wear on the running face. If any discoloration or burn marks are observed, replace. Run a fingernail or a pencil tip across the diameter of the sealing land surface. No deep or outstanding grooves should be felt, as these may decrease pump flow. Lap or replace if grooves or nicks are present. Inspect the mating surfaces of the end cap and valve plate for any possible contamination. Measure the thickness of the valve plate (21). Ensure that valve plate parallelism is equal to or less than 0.025 mm (0.0010 in). Appearance should be flat and smooth on both the running face and the bottom surface. The valve plate should be flat to 0.005 mm (0.0002 in) convex. Carry out a magnetic particle inspection to detect possible cracks. The plate (21) must be replaced in case of cracks.

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Copyright © 40


Check the cover (26). Remove the check valve (22) to expose the spring (23). Check and record orientation of the pin (20). The split in the pin should be facing into or out of the slot in the valve plate. Inspect the check valve (22) for wear on its sealing face. Make sure the spring (23) is undamaged. Replace any components if excess wear is present.

Check that the piston assy (16) for any obvious wear or damage. Check the corresponding end cap bore for galling or excessive wear.

Inspect the pump body (3) to ensure that it is clean and free of foreign material. Inspect the surfaces of the cradle bearings and the mating surfaces of the end cover.

The bearings (8) consist of a race (B) and a cone (A). Make sure the cup (B) and cone (A) are free of excessive wear or contamination. Rotate the bearing to check for smoothness. If a contaminated bearing is suspected, clean with solvent and lubricate with hydraulic oil. Inspect for uneven wear.

Copyright © SECTION 35 - HYDRAULIC SYSTEM Assembly Coat the cradle bearings (10) with oil and install them into the pump body (3). Insert the pins (11) a minimum of 0.5 mm (0.02 in) below the bearing surface. If the bearings (10) are reused, reinstall them in their original position. Install the bearing (8). Before replacing the spring (15), coat the contact surface of the swash plate (14) with oil. Assemble the swash plate (14), and the piston (16) and the spring (15) into the pump body (3). Rotate the piston (16) perpendicularly to the swash plate (14) and, at the same time, compress the spring (15) to fit it into the pump body (3). Liberally lubricate all sides of the piston (16) and its relevant bore and also the flat face of the swash plate to prevent premature wear during start-up. Insert the shaft (9) through the bearing in the body. Push on the piston to rotate the swash plate in order to put the shaft in properly. Lubricate components before assembly. Install the inner washer (36), the spring (37) and the outer washer (38) into the cylinder (35). Compress the spring enough to insert the ring (39).

WARNING Compressing the spring (37) requires about 350 ÷ 400 N (79 ÷ 90 lbf). Use a press sufficient to maintain this force. Ensure that the spring is secure before attempting to assemble the ring (39). Release the pressure slowly after the ring (39) has been installed. Turn the cylinder over and assemble the pins (34) and the ball guide (33) into the cylinder (35). Assemble the pistons (31) on the piston disc (32). Install the piston/disc assy into the cylinder (35). Ensure the concave surface of the disc seats correctly in the ball guide. If reusing the pistons, install them to the original cylinder bores. Lubricate the pistons (31), the piston disc (32) and the ball guide (33) before assembly. IMPORTANT: make sure to install the piston disc (32) so that it mates correctly with the articulation (33), the concave side of the disc against the convex side of the ball guide.

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Copyright © 42


Secure the end of the shaft with one hand and keep it horizontal. Insert the cylinder assy (17) onto the shaft (9). While holding the shaft still, slightly rotate the cylinder assy (17) to help position the shaft splines over the ball guide and align them with the cylinder splines. When the cylinder slides completely over the shaft splines, reposition the body with the flange facing downward.

Clean the valve plate (21) and the end cap. Assemble the pin (20) in the end cap (26) and verify that it is properly oriented with the split facing into or out of the slot in the valve plate (21). The pin should be installed to 3.61 ± 0.25 mm (0.1421 ± 0.0098 in) above the valve plate (21) surface. Apply a liberal amount of grease to the backside of the valve plate (21) surface to hold it in position. Assemble the valve plate (21) over the pin (20). Assemble the spring (23) and the check valve (22). To ensure proper pump operation, it is extremely important to guarantee that there is no contamination between the end cap (26) and the valve plate (21). Assemble the bearing cup (19). Assemble the bearing race (19) onto the shaft (9). Apply some grease to keep the O-ring (18) in place. Assemble the cover (26) to the body (3). Screw in and tighten the screws (27) to a tightening torque of 127 ÷ 155 Nm (94 ÷ 114 lbf·ft).

Copyright © SECTION 35 - HYDRAULIC SYSTEM Lubricate the seal ring (2) with oil. Place a protective sleeve over the shaft end (9) to prevent damage to the seal ring during installation. Holding the seal ring (2) perpendicular to the shaft (9), press it into the body just far enough to clear the ring groove. Assemble with the concave side towards the shaft bearing. Assemble the snap ring (1).

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Copyright © 44


CONTROL VALVES The hydraulic circuit is a load-sensing flow sharing system working together with a hydraulic pump. This system has the advantage that at any time the distribution of flow to the services being operated is in proportion to the openings of the control valve spools. The flow distribution to the backhoe and loader control valves is independent of the load and it is therefore possible to operate two or more spools at the same time. Important components of the system are the pressure compensator valves in each control valve section, together with the load-sensing line which connects all spools of the loader and backhoe attachment control valves. With the fixed-flow-rate hydraulic pump, the loadsensing line only connects the loader and backhoe attachment control valves and does not have any connection to the hydraulic pump. The hydraulic pump draws oil from the tank and flow from the front pump is directed to the centre galleries of the loader and backhoe control valves assemblies. The flow coming from the rear section of the pump passes through the flow divider valve and sends the priority flow to the steering system, while the remaining flow adds to the flow from the front pump, directed to the loader and backhoe attachment systems. The centre gallery of both the loader and backhoe control valves are blocked by the end plate. Pressure in the supply system is controlled by the pump flow balancer valve in accordance with the pressure in the load-sensing line. Consequently, the higher the load sensing pressure is, the less flow is returned to the tank, with a corresponding increase in flow/pressure to the hydraulic systems. Maximum system pressure is limited by the load sense pressure relief valve which relieves pressure in the load sense line when it reaches 210 bar (304 psi). Since the flow balancer valve is influenced by the load-sensing pressure, the valve diverts a sufficient quantity of oil to the tank to maintain the maximum system pressure of 210 bar (304 psi).

LOADER CONTROL VALVE The loader control valve is mounted on the right side of the machine adjacent to the pump. The control valve assembly consists of a maximum of three sections and provides oil to the loader attachment, to the bucket and to the 4x1 bucket, if installed. BACKHOE ATTACHMENT CONTROL VALVE The backhoe attachment control valve is located in the rear part of the machine. The control valve consists of a maximum of 7 or 8 sections and provides the oil flow for operating the lifting, the digging, the bucket, the stabilizers, the swing, the (optional) telescopic arm and the auxiliary services, if installed.

Copyright © SECTION 35 - HYDRAULIC SYSTEM SYSTEM DIAGRAM (BACKHOE ATTACHMENT MECHANICAL CONTROLS)

Hydraulic system oil

Suction oil

Steering system oil

Return to oil tank

Load-sensing line oil 1. Hydraulic tank

8. Backhoe hammer control valve

2. Hydraulic pump

9. Backhoe hammer

3. Power steering

10. Oil cooler

4. Hand hammer control valve

11. Return line distributor block

5. Hand hammer

12. Filter

6. Backhoe attachment control valve

13. Oil cooler by-pass valve

7. Loader attachment control valve

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Copyright © 46


SYSTEM DIAGRAM (BACKHOE ATTACHMENT PILOT CONTROLS)

Hydraulic system oil

Suction oil

Steering system oil

Return to oil tank

Load-sensing line oil

Control circuit oil

1. Hydraulic tank

9. Backhoe hammer

2. Pump

10. Oil cooler

3. Power steering

11. Return line distributor block

4. Hand hammer control valve

12. Filter

5. Hand hammer

13. Oil cooler by-pass valve

6. Backhoe attachment control valve 7. Loader attachment control valve

14. Solenoid valve for piloting backhoe control valve

8. Backhoe hammer control valve

15. Hydraulic control lever 16. Accumulator

Copyright © SECTION 35 - HYDRAULIC SYSTEM OIL FLOW OPERATION All loader/backhoe attachment systems are in neutral position Each control valve section within the backhoe or loader control valve assemblies contains a spool, two check valves and a load-sensing pressure compensator. A load-sensing gallery connects the compensators in each control valve section. When all control valves are in neutral position, the spools stop the oil flow in each system and the pressure of the load-sensing line can bleed to the tank through the relevant return-to-tank port. Because there is no load sense pressure being applied to the rear face of the flow balancer valve, the valve will move against the spring and off its seat when pump pressure reaches 15 bar. The pump flow is now diverted back to the tank and the balancer valve maintains a stand-by pressure of 15 bar while the systems are in neutral position.

Flow balancer valve operation - All spools in neutral Pump stand-by pressure 15 bar

Return to oil tank

1. Load sense bleed orifice 1 l/min

4. Load sense line

2. Load-sensing limiter (system pressure relief valve)

5. Pump flow balancer (unload) valve

3. Return to oil tank

7. To backhoe control valves

6. Pump flow IN

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Copyright © 48


Load sensing flow sharing - All spools in neutral Pump pressure

Return to oil tank

Trapped oil 1. Load non-return check valve

3. Pressure compensator

2. Load sense line

4. Spool


49

One hydraulic circuit operating When a single hydraulic circuit is operated the spool in the control valve section is moved allowing oil to flow past the lands of the spool and apply pressure to the metering element of the pressure compensating valve. The metering element moves upwards to allow oil to flow to the load check valve and at the same time uncovers the drilling in the spool portion of the pressure compensator valve enabling operating pressure to be sensed in the load sense gallery. As pressure increases to open the check valve, the load-sensing pressure is applied to the spring side of the flow balancer valve.

When pump pressure overcomes the pressure behind the load check valve, the valve opens allowing oil to flow into the cylinder port. Exhaust oil from the cylinder returns to tank through the other port in the control valve section. If pressure in a load-sensing system reaches 195 bar (2828 psi), the relief valve is activated. Pump pressure is now limited to 210 bar (304 psi). This is the pressure required to overcome the pressure of the flow balancing valve spring [15 bar (217 psi)] plus the load sensing pressure controlled at 195 bar (2828 psi).

A higher pressure is now required to operate the flow balancer valve and pump pressure increase accordingly.

Flow balancer valve operation - Hydraulic systems operating Pump pressure Load-sensing pressure Return to oil tank 1. Load sense bleed orifice 1 l/min

4. Load sense line

2. Load-sensing limiter (system pressure relief valve)




6. Pump flow IN

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Load sensing flow sharing - One spool operating Pump pressure Trapped oil Return to oil tank 1. Load non-return check valve


2. Load sense line

4. Spool


51

Two or more hydraulic systems operating When two or more hydraulic systems operate, each system operates at a different pressure. If pump flow to a specific system is not controlled, the system requiring a lower operating pressure will work faster than the system requiring a higher pressure, because the flow will have to overcome less resistance. To prevent this situation, the pressure compensating valve regulates the oil flow directed to the system operating at a lower load. When two spools are operated simultaneously pump pressure is applied to the metering element of the pressure compensating valve in both valve sections. Both metering elements therefore move upwards allowing oil to flow to the load check valves. At the same time, the port in the spool section of the pressure compensating valve is uncovered to allow operating pressure to be sensed in the load-sensing gallery.

Pump pressure will rise until it exceeds the pressure of the check valve of the system operating at the heaviest load and the pressure in the load sensing line has a value similar to that of the high pressure. The pressure required to operate the system with a lower load is now too high and, if not limited, it will result in this system operating instead of and faster than the system with a higher load. To compensate for this condition, the load sensing pressure moves the metering element of the pressure compensating valve in the system with a lower load downwards and restricts the flow to the system. This balancing of flow and pressure according to the load ensures that both systems operate simultaneously and at a balanced flow rate.

Load sense relief valve operating Pump pressure at 210 bar (304 psi)

Return to oil tank

Load sense pressure at 195 bar (2828 psi) 1. Load sense bleed orifice 1 l/min (0.22 gal/min)


2. Load sense limiter (system relief valve)

6. Pump flow IN



4. Load sense line

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Load sensing flow sharing - Two spools operating 1st spool operating pressure

Trapped oil

2nd spool operating pressure

Return to oil tank

1. Load non-return check valve


2. Load sense line

4. Spool

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. This control valve may be of 2 types, similar to each other, according to the hydraulic pump assembled to the machine: - gear pump (with fixed flow rate); - piston pump (with variable flow rate). The control valve consists of 2 or 3 sections, an end cover and an inlet section. The 3 control valve sections are: - loader attachment lifting; - loader bucket; - 4x1 loader bucket. The loader attachment control valve has three sections when the 4x1 bucket is installed on the machine. LOADER ATTACHMENT CONTROL VALVE WITH GEAR PUMP (WITH FIXED FLOW RATE)

A. 4x1 loader bucket section B. Bucket section C. Loader attachment lifting section 1. End cover 2. Bucket relief valve (rod side) - 240 bar (3481 psi) 3. Bucket relief valve (piston side) - 165 bar (2393 psi) 4. Hydraulic speed relief valve - 165 bar (2393 psi) 5. 4x1 bucket relief valve - 240 bar (3481 psi) 6. Hydraulic speed solenoid 7. Inlet spool

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LOADER ATTACHMENT CONTROL VALVE WITH PISTON PUMP (WITH VARIABLE FLOW RATE)

A. 4x1 loader bucket section B. Bucket section C. Loader attachment lifting section 1. End cover 2. Bucket relief valve (rod side) - 240 bar (3481 psi) 3. Bucket relief valve (piston side) - 165 bar (2393 psi) 4. 4x1 bucket relief valve - 240 bar (3481 psi) 5. Inlet spool

Copyright © SECTION 35 - HYDRAULIC SYSTEM CONTROL VALVE REMOVAL FROM MACHINE Move the machine to a level and firm ground, away from any soft ground, excavations and poorly shored cavity. Lower the loader attachment to the ground. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Lower the stabilizers to the ground. Stop the engine and remove the starter key. Release the hydraulic pressure by operating the control levers in all directions. On hydraulically controlled machines, turn the key to ON and release the pressure by moving the hydraulic control levers in all directions. Place some wedges under the wheels so as to prevent the machine from moving. Disconnect the electric system by disconnecting the battery master switch. Drain oil from the hydraulic system. Disconnect the battery. Clean the area around the control valve. Identify and disconnect the articulations, cables and hoses and plug the hose ends. A drip tray will be required to catch oil draining from inside the hoses. Loosen and remove the fastening screws. Remove the control valve assembly from the machine. For installation, follow the removal procedure in reverse order.

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DISASSEMBLY Loosen and remove the 3 nuts (1). [Tightening torque = 27 ± 2 Nm (19.91 ± 1.47 lbf·ft)] Extract the 3 tie rods (2).

Remove the end cover (7). Disassemble the sections of the control valve (4), (5) and (6) and the inlet section (3). Check and, if necessary, replace the O-rings (8) located between the different sections of the control valve.

Copyright © SECTION 35 - HYDRAULIC SYSTEM BACKHOE ATTACHMENT CONTROL VALVE The backhoe attachment control valve is located in the rear part of the machine. The backhoe attachment control valve may be of 2 types, similar to each other, according to the hydraulic pump installed on the machine: - gear pump (with fixed flow rate); - piston pump (with variable flow rate); Furthermore, the backhoe attachment control valves are divided into: - control valves for backhoe attachment mechanical controls; - control valves for backhoe attachment pilot controls. The backhoe attachment control valve may consist of 6 or 7 or 8 sections, an end cover and an inlet section. The possible 8 sections are: - right-hand stabilizer; - left-hand stabilizer; - boom; - digging; - swing; - bucket; - telescopic dipper (optional); - auxiliary attachment (only optional on control valves for backhoe attachment pilot controls).

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BACKHOE ATTACHMENT CONTROL VALVE - BACKHOE ATTACHMENT MECHANICAL CONTROLS The backhoe attachment control valves for machines with backhoe attachment mechanical controls may have 6 or 7 sections (and not 8 sections). With gear pump (with fixed flow rate)

A. Right stabilizer section

1. End cover

B. Left stabilizer section

2. Inlet section

C. Dipper section

3. Dipper relief valves - 240 bar (3481 psi)

D. Bucket section

4. Bucket relief valve (rod side) - 260 bar (3771 psi)

E. Swing section

5. Bucket relief valve (piston side) - 220 bar (3191 psi)

F. Boom section

6. Swing relief valve - 205 bar (2973 psi)

G. Telescopic dipper section

7. Boom relief valve (rod side) - 240 bar (3481 psi) 8. Boom relief valve (piston side) - 310 bar (4496 psi) 9. Telescopic dipper relief valve - 124 bar (1798 psi) 10. Pump flow rate balancer valve - 10 bar (145 psi)


59

With piston pump (with variable flow rate)

A. Right stabilizer section

1. End cover

B. Left stabilizer section

2. Inlet section

C. Dipper section

3. Dipper relief valves - 240 bar (3481 psi)

D. Bucket section

4. Bucket relief valve (rod side) - 260 bar (3771 psi)

E. Swing section

5. Bucket relief valve (piston side) - 220 bar (3191 psi)

F. Boom section

6. Swing relief valve - 205 bar (2973 psi)

G. Telescopic dipper section

7. Boom relief valve (rod side) - 240 bar (3481 psi) 8. Boom relief valve (piston side) - 310 bar (4496 psi) 9. Telescopic dipper relief valve - 124 bar (1798 psi) 10. Pump flow rate balancer valve - 10 bar (145 psi)

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CONTROL VALVE REMOVAL FROM MACHINE Move the machine to a level and firm ground, away from any soft ground, excavations and poorly shored cavity. Lower the loader attachment and the backhoe attachment to the ground. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Lower the stabilizers to the ground. Stop the engine and remove the starter key. Release the hydraulic pressure by operating the control levers in all directions. On hydraulically controlled machines, turn the key to ON and release the pressure by moving the hydraulic control levers in all directions. Place some wedges under the wheels so as to prevent the machine from moving. Disconnect the electric system by disconnecting the battery master switch. Drain oil from the hydraulic system. Disconnect the battery. Clean the area around the control valve. Identify the position of all hoses to be disconnected and tag them. Disconnect the hoses and plug their ends. Disconnect the manual control levers. Loosen and remove the fastening screws. Remove the control valve assembly from the machine. For installation, follow the removal procedure in reverse order.

Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY AND ASSEMBLY Loosen and remove the 3 nuts (1). [Tightening torque = 27.2 Nm (20.06 lbf·ft)] Extract the 3 tie rods (2).

Remove the end cover (3). Disassemble the sections of the control valve (4), (5), (6), (7), (8), (9) and (10) and the inlet section (11). Check and, if necessary, replace the O-rings (12) located between the different sections of the control valve.

Inlet section disassembly Remove the flow balancer valve (13). [Tightening torque = 100 Nm (73.76 lbf·ft)] Remove the load-sensing valve (14). [Tightening torque = 45 Nm (33.19 lbf·ft)] Remove the pressure relief valve (15). Unscrew and remove the plugs (16) and (17). Unscrew and remove the plug (18). [Tightening torque = 20 Nm (15 lbf·ft)]

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Disassembly of the end cover Remove the relief valve (19). Remove the valve (20).

Disassemble the control valve sections

NOTE: The figure shows the stabilizer section, the valves may be different in the other sections.

- loosen and remove the pin (25); [Tightening torque = 10 Nm (7.4 lbf·ft)]

Remove the check valves (21). [Tightening torque = 30 Nm (22 lbf·ft)]

- extract the spring (27) with the relevant spring guides (26);

Remove the flow balancer valve (22). [Tightening torque = 60 Nm (44 lbf·ft)]

- keep the seal (29).

Remove the pressure relief valves (37). [Tightening torque = 70 Nm (52 lbf·ft)]

Remove the spool: - loosen and remove the screws (23); [Tightening torque = 10 Nm (7.4 lbf·ft)] - remove the cover (24) and the seal (28);

- loosen and remove the yoke (30) with the protection (31); [Tightening torque = 10 Nm (7.4 lbf·ft)] - loosen and remove the screws (32); [Tightening torque = 10 Nm (7.4 lbf·ft)] - remove the flange (33) with the relevant seal (34); - keep the seal (35); - extract the spool (36).

Copyright © SECTION 35 - HYDRAULIC SYSTEM Assembly of spool seals Position the metal part of the seal (29) on the outside of the spool (36). The seal must be fitted on the end of the spool so that its grooves (S) are not damaged and its tightness is not jeopardized. Let the seal slide perpendicularly onto the spool.

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Copyright © 64


BACKHOE ATTACHMENT CONTROL VALVE - BACKHOE ATTACHMENT PILOT CONTROLS The backhoe attachment control valves for machines with backhoe attachment pilot controls may have 6 or 7 or 8 sections. With gear pump (with fixed flow rate)

A. Right stabilizer section B. Left stabilizer section C. Dipper section D. Bucket section E. Swing section F. Boom section G. Telescopic dipper section H. Auxiliary section 1. End cover 2. Inlet section 3. Dipper relief valves - 220 bar (3191 psi)

4. Backhoe bucket relief valve (rod side) - 260 bar (3771 psi) 5. Backhoe bucket relief valve (piston side) 220 bar (3191 psi) 6. Swing relief valve - 205 bar (2973 psi) 7. Boom relief valve (rod side) - 124 bar (1798 psi) 8. Boom relief valve (piston side) - 310 bar (4496 psi) 9. Telescopic dipper relief valve - 124 bar (1798 psi) 10. Auxiliary section relief valves - 220 bar (3191 psi) 11. Pump flow rate balancer valve - 10 bar (145 psi) 12. Load-sensing relief valve - 205 bar (2973 psi)


65

With piston pump (with variable flow rate)

A. Right stabilizer section B. Left stabilizer section C. Dipper section D. Bucket section E. Swing section F. Boom section G. Telescopic dipper section H. Auxiliary section 1. End cover 2. Inlet section 3. Dipper relief valves - 220 bar (3191 psi)

4. Backhoe bucket relief valve (rod side) - 260 bar (3771 psi) 5. Backhoe bucket relief valve (piston side) 220 bar (3191 psi) 6. Swing relief valve - 205 bar (2973 psi) 7. Boom relief valve (rod side) - 124 bar (1798 psi) 8. Boom relief valve (piston side) - 310 bar (4496 psi) 9. Telescopic dipper relief valve - 124 bar (1798 psi) 10. Auxiliary section relief valves - 220 bar (3191 psi) 11. Pump flow rate balancer valve - 10 bar (145 psi)

Copyright © 66


CONTROL VALVE REMOVAL FROM MACHINE Move the machine to a level and firm ground, away from any soft ground, excavations and poorly shored cavity. Lower the loader attachment and the backhoe attachment to the ground. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Lower the stabilizers to the ground. Stop the engine and remove the starter key. Release the hydraulic pressure by operating the control levers in all directions. On hydraulically controlled machines, turn the key to ON and release the pressure by moving the hydraulic control levers in all directions. Place some wedges under the wheels so as to prevent the machine from moving. Disconnect the electric system by disconnecting the battery master switch. Drain oil from the hydraulic system. Disconnect the battery. Clean the area around the control valve. Identify the position of all hoses to be disconnected and tag them. Disconnect the hoses and plug their ends. Disconnect the manual control levers. Loosen and remove the fastening screws. Remove the control valve assembly from the machine. For installation, follow the removal procedure in reverse order.

Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY AND ASSEMBLY Loosen and remove the 3 nuts (1). [Tightening torque = 27.2 Nm (20.06 lbf·ft)] Extract the 3 tie rods (2).

Remove the end cover (3). Disassemble the sections of the control valve (4), (5), (6), (7), (8), (9), (10) and (11) and the inlet section (12). Check and, if necessary, replace the O-rings (13) located between the different sections of the control valve.

Inlet section disassembly Remove the flow balancer valve (19). [Tightening torque = 100 Nm (73.76 lbf·ft)] Remove the load-sensing valve (14). [Tightening torque = 45 Nm (33.19 lbf·ft)] Remove the pressure relief valve (15). Unscrew and remove the plugs (16) and (17). Unscrew and remove the plug (18). [Tightening torque = 20 Nm (15 lbf·ft)]

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Copyright © 68


Disassembly of the cover Remove the relief valve (21). Remove the valve (20).

Disassemble the control valve sections

NOTE: the figure shows the swing section, the valves may be different in the other sections. Remove the check valves (22). [Tightening torque = 30 Nm (22 lbf·ft)] Remove the flow balancer valve (24). [Tightening torque = 60 Nm (44 lbf·ft)] Remove the pressure relief valve (23). [Tightening torque = 70 Nm (52 lbf·ft)]

Remove the spool: - loosen and remove the screws (26); [Tightening torque = 10 Nm (7.4 lbf·ft)] - remove the cover (27);

- if necessary, replace the O-ring (28); - remove the spring (29) and the relevant spring guide (30); - loosen and remove the screws (31); [Tightening torque = 10 Nm (7.4 lbf·ft)] - remove the cover (32); - if necessary, replace the O-ring (33); - remove the spring (34) and the relevant spring guide (35); - extract the spool (25).

Copyright © SECTION 35 - HYDRAULIC SYSTEM RELIEF VALVES There are different relief valves installed on the loader and backhoe attachment control valves. The relief valves may be operated with anti-cavitation feature (1) or direct acting (2) and protect the single systems from excessive pressure.

OPERATION Relief valve inoperative When the system is not subject to overload conditions pressure in the system is insufficient to overcome pilot valve spring pressure and move the valve of its seat. System pressure sensed on the larger rear face of the poppet valve maintains the poppet and sleeve firmly on their seats. 1. Sleeve 2. Poppet valve 3. Pilot valve 4. Pilot valve body 5. Piston 6. Control valve (cylinder) exhaust gallery 7. Cylinder supply gallery

Exhaust oil High pressure oil

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Copyright © 70


Pilot valve operation When the cylinder is subjected to shock forces, the pressure increase in the cylinder supply gallery exceeds the pilot valve spring pressure: this valve lifts off its seat. System pressure on the rear face of the poppet valve escapes to tank between the sleeve poppet and valve body causing a pressure differential between the front and rear face of the poppet valve. The higher pressure in the cylinder supply gallery unseats the poppet valve and moves the piston to seat against the pilot valve. 1. Sleeve 2. Poppet valve 3. Pilot valve

Exhaust oil High pressure oil Reduced pressure oil

4. Pilot valve body 5. Piston 6. Control valve (cylinder) exhaust gallery 7. Cylinder supply gallery Pilot and poppet valve operation The excessive system pressure in the cylinder supply gallery now flows past the poppet valve to the cylinder exhaust gallery and back to tank. NOTE: during this operation the sleeve poppet is held in the fully seated position by pressure oil. 1. Sleeve 2. Poppet valve 3. Pilot valve 4. Pilot valve body 5. Piston 6. Control valve (cylinder) exhaust gallery 7. Cylinder supply gallery

High pressure oil Exhaust oil Reduced pressure oil

Copyright © SECTION 35 - HYDRAULIC SYSTEM Anti-cavitation operation Relief valves with an anti-cavitation feature are fitted in systems where a rapid extension of the cylinder could create a void condition and permit the transfer of oil from the high pressure side of a cylinder to the low pressure (void) side. When for example the boom is rapidly lowered and the cylinder rod end circuit relief valve operates, oil has been removed from the rod end of the cylinder and a void created in the piston end. This oil is automatically replenished by the anti-cavitation device in the opposite circuit relief valve as follows: The void creates a pressure lower in the cylinder supply gallery and back pressure in the control valve exhaust gallery acts on the outer face of the sleeve poppet moving it to the right. Exhaust oil is then directed into the cylinder supply gallery to stop cavitation.

High pressure oil

Relief valve exhaust oil

Anti-cavitation oil supply to cylinder

1. Anti-cavitation system pressure relief valve

4. Control valve exhaust gallery

2. Cylinder rod

5. Spool

3. System pressure relief valve

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Copyright © 72


Pilot-operated pressure relief valve with anti-cavitation feature subjected to overload and fully relieving high-pressure oil 1. Sleeve 2. Poppet valve 3. Pilot valve 4. Pilot valve body 5. Piston 6. Control valve (cylinder) exhaust gallery 7. Cylinder supply gallery Anti-cavitation cylinder resupply oil Exhaust oil Direct-acting pressure relief valve operation High-pressure oil in the system is sensed in the cylinder supply gallery and acts on the surface of the pressure relief valve poppet. When pressure in the system exceeds the pressure relief valve setting, the oil pressure lifts the poppet, allowing excess pressure in the overloaded cylinder to escape to the drain gallery.

A. Direct acting circuit relief valve Valve not subjected to overload conditions B. Direct acting circuit relief valve Valve subjected to overload conditions 1. Relief valve seat 2. Relief valve poppet 3. Valve pressure adjusting screw 4. Spring 5. Control valve exhaust gallery 6. Cylinder supply oil Exhaust oil High-pressure system oil

Copyright © SECTION 35 - HYDRAULIC SYSTEM OVERHAUL Before removing the relief valves from the machine, lower the loader and backhoe attachment to the ground, stop the engine and relieve pressure in all systems by moving the backhoe attachment, loader attachment and telescopic dipper controls through all operating positions. If the pressure relief valves are suspected of contamination, they may be disassembled and inspected for wear. During assembly, restore the correct pressure. During disassembly examine the poppet and seat in the plunger assembly for a complete seating surface. Pilot operated relief valve

1. Body

9. O-ring

2. Shutter

10. Nut

3. Spring

11. O-ring

4. Spring

12. Adjusting screw

5. O-ring

13. Spring

6. O-ring

14. Pilot valve

7. Valve

15. Poppet

8. Cover

16. Piston

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Copyright © 74


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. Adjusting screw

Loader bucket relief valve

1. Relief valve assembly 2. Spring

7. Piston

3. Nut

8. Poppet

4. Body

9. Valve

5. Adjusting screw

10. Inner body

6. Spring

11. Spring seat

Copyright © SECTION 35 - HYDRAULIC SYSTEM ADJUSTMENTS System pressure relief valve adjustment After overhaul, the pressure relief valves of the system must be tested and adjusted using a suitable hand pump (1), a 275 bar (3988 psi) pressure gauge and a V. L. Churchill test kit (2).

The hand pump must be attached to inlet port and the drain hose to the outlet port T of test block using suitable 1/2” BSP (British Standard Pipe) adaptors. The pressure gauge may be connected to either the hand pump or to the 3/8 UNF threaded port G in the test block. Remove the plug and insert the valve to be tested into the appropriate port in the test block: A. Stabilizer and backhoe relief valves B. Loader bucket relief valves C. Unload valve NOTE: a special removable insert, which is part of the test block, is installed in the bottom part of the port used for testing the loader attachment valve. If difficulty is experienced in screwing the loader valve into the test block, check that the insert is fully seated and correctly installed. When correctly installed the O-ring (3) on the face of the insert should be visible.

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Copyright © 76


Operate hand pump and record maximum pressure reading on gauge. Compare pressure values with previous specifications. IMPORTANT: before removing the valve from the test block, release the pressure in the system using the vent valve on the hand pump.

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. IMPORTANT: relief valves must not be set outside off the specified range.

Loader bucket relief valve adjustment If the loader bucket circuit relief valve requires adjustment, use the special adjusting tool supplied with the test kit. Hold relief valve in vice and using wrench supplied with tool, unscrew the internal valve assembly from the valve body. Screw the internal valve assembly (2) into the body of the adjusting tool (1).

Install valve into test block and operate hand pump until valve is pressurized to 170 bar (2466 psi). Using the special wrench supplied, loosen the locknut on the end of the valve and adjust pressure setting. Operate hand pump and recheck pressure. When pressure setting is correct tighten locknut and release pressure in circuit using the vent valve on the hand pump. Remove the valve and, using a 3/8” 16 UNC screw, remove the insert.

Copyright © SECTION 35 - HYDRAULIC SYSTEM Reassemble the valve and install it on the test block. Operate hand pump and recheck pressure. If pressure is now lower than that recorded with the insert installed it is an indication that the anti-cavitation feature of the valve is leaking and the valve requires overhaul or replacement. The insert isolates the anti-cavitation feature of the valve. When reassembling the insert into the test block ensure it is installed correctly. When correctly installed the O-ring (3) on the face of the insert should be visible.

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BACKHOE ATTACHMENT CONTROL VALVE PILOT SOLENOID VALVE

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 on backhoe loaders with backhoe attachment pilot controls and has the task to transform the electric controls, received from the control levers, into hydraulic controls, and to send them to the backhoe attachment control valve. The module (A) is installed only on the machines versions with telescopic dipper. If the machine is not equipped with telescopic dipper, the solenoid valve installed is of type (B); while if the telescopic dipper is installed the solenoid valve can be of type (A) + (B).

Copyright © SECTION 35 - HYDRAULIC SYSTEM If the backhoe loader is equipped with a telescopic dipper and if the rear control valve contains an auxiliary section, the solenoid valve consists of valve (B) and module (C).

DISASSEMBLY Unscrew and remove the accumulator (1) from the solenoid valve assy (2).

Loosen and remove the three screws (3) and disassemble valve (4). Check and replace the O-rings (5), if necessary.

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If necessary, it is possible to disassemble the various solenoid valves: - disassemble the solenoid valves (7) by loosening the screws (6); - loosen and remove the valve (8); - loosen and remove the solenoid valves (9) and (10); - check and replace the O-rings, if necessary.


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ACCUMULATOR “GLIDE RIDE” PARKER TECHNICAL SPECIFICATIONS Capacity (gas)...........................................................................................................................2 litres (0.44 gal) Capacity (oil) ........................................................................................................................1.84 litres (0.40 gal) Precharge .................................................................................................................. 30 ± 1 bar (4354 ± 14 psi)

MAINTENANCE

SAFETY

Regularly check the gas pre-charge pressure during the first few weeks of operation.

Charging must be carried out by qualified personnel.

Then check at suitable intervals based on this initial experience.

Before taking any readings or pressurizing with nitrogen, the accumulator must be isolated from the hydraulic system and the fluid side discharged in order to depressurize it.

Carry out a visual examination of the accumulator periodically in order to detect any early signs of deterioration such as corrosion, deformation etc. Comply with the regulatory provisions concerning the monitoring of operational equipment. Before removal, make sure that there is no residual pressure in the accumulator. Before carrying out any maintenance operation, discharge the gas of the accumulator using a Parker UCA charging and measuring device.

Use only nitrogen (N2) to pressurize the accumulator. Danger of Explosion - Never Charge with Oxygen The types of nitrogen permitted are: - type S (99.8% pure); - type R (99.99% pure); - type U (99.993% pure). If the pressure of the gas contained in the nitrogen bottle is greater than the maximum permissible operating pressure of the accumulator, a pressure regulator must be fitted to the nitrogen bottle. The precharge should be checked during the first week following commissioning of the system. Thereafter, it should be checked every three months, or at intervals determined by the Manufacturer. Effect of temperature on precharge pressure In order to compensate for the difference in pressure at ambient and operating temperature, the precharge pressure po should be adjusted according to the operating temperature of the system. Stabilization The process of charging or discharging an accumulator with nitrogen causes a temperature change which is transmitted to the surrounding air as the temperature of the accumulator stabilizes. To allow for the effects of temperature transfer, the accumulator should be allowed to stand for a minimum of 15 minutes before a final reading of the precharge pressure is taken.

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CHECKING AND ADJUSTING THE PRECHARGE PRESSURE To check the precharge pressure of the accumulator, it is necessary to have the universal charging and measuring kit UCA 380002714. The kit must be screwed onto the accumulator’s gas valve, allowing the precharge pressure to be checked and reduced. If the precharge pressure is to be increased, the UCA can be connected to the nitrogen source with the hose supplied. The kit includes two pressure gauges for readings of 0 ÷ 25 bar (0 ÷ 363 psi) and 0 ÷ 250 bar (0 ÷ 3626 psi) If a different pressure interval becomes necessary, use a pressure gauge available in commerce. Kit UCA 380002714 A. Inflation valve B. Bleed valve 1. UCA 2. Adapter (long) 3. Adapter (short) 4. Adapter (insert) 5. Pressure gauge 6. Protective cap - gauge port 7. Collar - gas port 8. Protective cap - filling port 9. Hose (1/4) with O-ring 10. Valve

Remove the protective cover and cap (11) from the accumulator, to gain access to the gas valve (12). Select the appropriate pressure gauge (5) for the pressure to be checked, remove the protective cap (6) and connect the port to the UCA (1). Make sure that the bleed valve (B) is fully closed and that the inflation valve (A) is fully raised by turning the handwheel in a counterclockwise direction. Assemble the short adapter and adapter insert (3) and (4), screw onto the gas valve (12) and hand tighten. Screw the UCA onto the adapter. Position the assembly to permit easy reading of the gauge, then hand tighten the collar (7). Open the inflation valve (A) by screwing the handwheel clockwise until the inflation pressure registers on the gauge.


83

READINGS AND RESULTS 3 conditions may become true. Nitrogen po pressure is correct

Screw the handwheel (A) counterclockwise to close the accumulator gas valve.

Screw the handwheel (A) counterclockwise to close the accumulator gas valve.

Slacken the bleed valve (B) to release pressure in the UCA.

Slacken the bleed valve (B) to release pressure in the UCA.

Remove the hose carefully, to release internal pressure.

Unscrew the UCA from the adapter.

Refit the cap (8) on the valve (10).

Unscrew the adapters from the accumulator gas valve.

Unscrew the UCA from the adapter(s).

Nitrogen po pressure is too high Slacken the bleed valve (B) to vent nitrogen from the accumulator until, after stabilization, the desired pressure po is registered. Nitrogen vents into the air. Tighten the bleed valve (B) once the desired filling pressure is reached. Screw the handwheel (A) counterclockwise to close the accumulator gas valve. Slacken the bleed valve (B) to release pressure in the UCA. Unscrew the UCA from the adapter. Unscrew the adapters from the accumulator gas valve. Nitrogen po pressure is too low Close the inflation valve (A) by screwing the handwheel counterclockwise. Remove the cap (8). Connect the end of the hose (9) to the valve (10). Connect the other end of the hose to the nitrogen source. Progressively open the valve on the nitrogen source. Turn the handwheel (A) clockwise to let pressurized gas in. Use special care if the accumulator has small capacity. When pressure po is reached, close the valve on the nitrogen source. To allow for the effects of temperature transfer, the accumulator should be allowed to stand for a minimum of 15 minutes to allow the temperature to stabilize before a final reading of the precharge pressure is taken.

Unscrew the adapters from the accumulator gas valve. After removing the UCA and adapter(s), make sure that the accumulator gas valve (12) is sealing effectively. Refit the gas valve dust cover (12) and replace the protective cover (11).

Copyright © 84


HYDRAULIC SWING SYSTEM OPERATION The hydraulic swing system has two versions: - Sideshift: it can shift laterally with the backhoe attachment because it is installed directly on the sideshift carriage performing the shifting; - Center pivot: it is fixed because it is installed directly on the chassis. The backhoe attachment may slew by 180° around the main frame. This movement is obtained by means of two hydraulic cylinders (1) installed between the main chassis and the backhoe attachment support. The cylinders act directly on the backhoe attachment support, with no need for connections or bell cranks. Each cylinder is free to rotate, around two pivots (3), while the stem comes out or retracts inside of the cylinder body (2). As each cylinder extends or retracts, the swing post and the cylinders turn, pivoting on the headstocks within the carriage. Each cylinder is double-acting and, as hydraulic oil is fed to a cylinder to turn the post, one cylinder pushes and the other cylinder pulls.


85

HYDRAULIC OIL FLOW Hydraulic feed to the swing cylinders is controlled by the swing section of the backhoe attachment control valve, which contains pilot-operated pressure relief valves with anti-cavitation feature to protect the system and the cylinders, should an overload condition occur. The diagram illustrates the operation of the swing circuit when retracting the right-hand cylinder (4) and extending the left-hand cylinder (5) in order to swing the backhoe attachment to the right. When swinging the backhoe to the left the oil flows are reversed and exactly the same principle of operation applies. The various operating stages for right swing are described below as an example. When the swing control is operated the control valve directs oil flow to the rod end of the right hand cylinder. The oil flow at pump pressure lifts the one-way restrictor (2) from its seat, thus allowing the flow to continue unrestricted to the inlet port of the piston end of the left-hand cylinder. System pressure increases causing the right hand cylinder to retract and the left hand cylinder to extend. As the cylinders move, displaced oil on the piston side of the left hand cylinder flows towards the one way restrictor (7) in the inlet port on the rod end of the right hand cylinder. The oil flow moves the restrictor to the restrict position which limits the flow of oil and creates a back pressure (1st stage restricted return oil) in the right hand cylinder. The restricted flow of oil passes through restrictor (7) into the rod end of the left hand cylinder before returning to the control valve and back to tank. The spool in the swing control valve (1) is designed so that, during operation, oil can flow freely through the port directing oil flow to the swing cylinders, but is restricted when going back to the tank. This restriction is achieved using metering lands machined into the lands of the spool and creates a secondary back pressure (2nd stage restricted return oil) in the rod end of the cylinder.

By allowing oil to flow unrestricted to the power side of the cylinder and be restricted on the exhaust side a smooth controlled swing of the backhoe at optimum speed is achieved. When the swing system reaches the last 20° - 25° of travel, the sliding restrictor on the end of the piston rod touches the outlet port of the cylinder barrel. This further restricts the flow of oil drained from the cylinder. As the piston moves towards the end of its stroke, the sliding restrictor is gently pushed down towards the centre of the cylinder rod, allowing a progressive and controlled stop of the swing cycle. If the swing control valve is suddenly returned to neutral mid-way through a full power swing the supply and exhaust ports in the main control valve are totally blocked. The momentum of the swinging backhoe assembly if not controlled will make the machine extremely unstable. To prevent this from occurring, the system pressure relief valves operate and drain the oil until an excess pressure is detected. When the relief valve operates the cylinder rod will move and a void will be created in the low pressure side of the cylinder. The anti-cavitation feature in the relief valves prevents the void from creating by transferring the drain oil from the side of the system where an excess pressure occurred to the low pressure side.

Copyright © 86


Pump pressure oil 1st stage restricted return oil 2nd stage restricted return oil Return to oil tank

1. Control valve swing section

5. Left hand cylinder

2. Limiter

6. Compressor rod

3. Cushioning rod

7. Limiter

4. Right hand cylinder


87

HYDRAULIC CYLINDERS

1. Loader attachment boom cylinder

7. Telescopic cylinder

2. Loader bucket cylinder

8. Swing backhoe cylinder

3. 4x1 loader bucket cylinder

9. Stabilizer cylinder (center pivot models)

4. Backhoe boom cylinder

10. Stabilizer cylinder (sideshift models)

5. Backhoe dipper cylinder

11. Backhoe sideshift locking cylinder (sideshift models)

6. Backhoe bucket cylinder

Copyright © 88


LOADER ATTACHMENT BOOM CYLINDER 2WS

1. Stroke 2. Completely retracted

2WS-TC


Copyright © SECTION 35 - HYDRAULIC SYSTEM LOADER ATTACHMENT BOOM CYLINDER REMOVAL Move the machine to a level and firm ground. Sufficiently raise the loader attachment to allow the boom cylinder pivot pin to be removed and securely support the front and rear part of the bucket with stands to prevent the loader attachment arms from lowering when the cylinder is disconnected. If the bucket cannot be safely supported, remove it and support the loader attachment arms using a suitable stand or hoist.

WARNING Always ensure that the loader is fully supported. Do not work under or near an unsupported loader attachment, to prevent the danger of personal injury. Relieve the residual pressure in the system by moving the loader control lever through all operating positions. Stop the engine. Support the cylinder using sling and suitable hoist. Disconnect the hoses. Cap or plug all exposed openings.

Remove the snap ring (1) and the spacer (2).

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Copyright © 90


Remove the ring (3) and the pin (4). Use a hammer to extract the rod pin (5).

Remove the loader attachment boom cylinder.

Copyright © SECTION 35 - HYDRAULIC SYSTEM LOADER ATTACHMENT BOOM CYLINDER DISASSEMBLY

1. Cylinder rod

9. Back-up ring

2. Bushing

10. O-ring

3. Wiper ring

11. Piston

4. Ring

12. Piston gasket

5. Seal ring

13. Piston guide rings

6. Guide bush

14. Screw

7. Cylinder head

15. Cylinder tube

8. Safety screw

16. Bushing

The disassembly procedure described below may start on the premise that the hydraulic lines have already been disconnected.

WARNING Cylinder weight (2WS): 32.5 kg (71.65 lb). Cylinder weight (4WS): 41.3 kg (91.05 lb). Lift and securely place the cylinder on a workbench. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

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Copyright © 92


Support the cylinder rod (1). Unscrew and remove the safety screw (8). Use wrench 380000725 to loosen the cylinder head (7). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture.

Remove the cylinder head (7) from the cylinder barrel (15) using a plastic hammer. Remove the cylinder rod (1) and the cylinder head (7). IMPORTANT: be sure to pull the cylinder rod (1) straight so as not to damage the sliding surfaces.

Loosen and remove the screw (14). Extract the piston (11) and the cylinder head (7) from the cylinder rod (1).

Only if necessary: - remove the wiper ring (3), the seal ring (4), the ring (5), the guide bush (6) and the back-up ring (9) with the O-ring (10) from the cylinder head (7); - remove the piston seal (12) and the piston guide rings (13) from the piston (11).

Copyright © SECTION 35 - HYDRAULIC SYSTEM LOADER BUCKET CYLINDER 2WS


4WS


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Copyright © 94


LOADER BUCKET CYLINDER REMOVAL Move the machine to a level and firm ground. Place the bucket firmly on the ground. Relieve the residual pressure in the system by moving the loader control lever through all operating positions. Support the cylinder using a sling or a suitable hoist. Disconnect the hoses. Cap or plug all exposed openings.

Support the link rods. Remove the snap ring (1) and the spacer (2). Use a hammer to extract the rod pin (3).

Remove the snap ring (4) and the spacer (5). Hammer to slide out the pin (6).

Remove the loader bucket cylinder.

Copyright © SECTION 35 - HYDRAULIC SYSTEM LOADER BUCKET CYLINDER DISASSEMBLY

1. Bushing

9. O-ring

2. Cylinder rod

10. Piston

3. Wiper ring

11. Piston gasket

4. Seal ring

12. Piston guide

5. Ring

13. Screw

6. Cylinder head

14. Cylinder tube

7. Snap ring

15. Bushing

8. Back-up ring

The disassembly procedure described below is based on the premise that the hydraulic hoses have already been disconnected.

WARNING Cylinder weight: 32.5 kg (71.65 lb). Lift and securely place the cylinder on a workbench. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

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Copyright © 96


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 snap ring (7). Extract the cylinder head (6) from the cylinder barrel (14) by tapping it with a plastic hammer. Remove the cylinder rod (2) and the cylinder head (6). IMPORTANT: be sure to pull the cylinder rod (2) straight so as not to damage the sliding surfaces.


Only if necessary: - remove the wiper ring (3), the seal ring (4), the ring (5), the back-up ring (8) with the O-ring (9) from the cylinder head (6); - remove the piston seal (11) and the piston guide ring (12) from the piston (10).

Copyright © SECTION 35 - HYDRAULIC SYSTEM 4X1 LOADER BUCKET CYLINDER

1. Cylinder rod pin 2. Dowel 3. Bucket 4. Cylinder 5. Dowel 6. Nut 7. Cylinder bottom pin

LOADER 4x1 BUCKET CYLINDER REMOVAL Move the machine to a level and firm ground. Place the bucket firmly on the ground. Relieve the residual pressure in the system by moving the loader control lever through all operating positions.

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Copyright © 98


Disconnect the hoses. Cap or plug all exposed openings.

Unscrew and remove the clamping screws of the cover (C). Remove the cover (C).

Remove the pin (2). Slide out the rod pin (1) with an hammer.

Unscrew and remove the nut (6) and the dowel (5). Slide out the lower pin (7) with an hammer.

Remove the 4x1 bucket cylinder.

Copyright © SECTION 35 - HYDRAULIC SYSTEM LOADER 4x1 BUCKET CYLINDER DISASSEMBLY

1. Cylinder tube

7. Cylinder head

2. Piston

8. Gasket

3. Pin

9. Wiper ring

4. O-ring

10. Cylinder rod

5. Piston guide

11. Bushing

6. O-ring

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Copyright © 100


BACKHOE BOOM CYLINDER

1. Stroke

590ST - 695ST

2. Completely retracted

BACKHOE ATTACHMENT BOOM CYLINDER REMOVAL Move the machine to a level and firm ground. Place the bucket firmly on the ground. Support the backhoe attachment elements for cylinder removal using a suitable support.

WARNING Always support the structural members so that they will be stable and safe to work around. Stop the engine and move the backhoe attachment control levers through all operating positions to relieve any residual pressures in the system. Position a sling or other suitable lifting equipment around the cylinder.

580T - 580ST

Copyright © SECTION 35 - HYDRAULIC SYSTEM Disconnect the hoses (T). Cap or plug all exposed openings. Remove the snap ring (1) and the spacers (2). Extract the pin (3) with a hammer.

Disconnect the yoke of the lock cylinder (4) for transport from the hook (5).

Extract the pin (6). Remove the hook (5) and the hook (8). Now it is possible to remove the rod pin (7) by tapping with a hammer on one side and extracting the pin from the other. Remove the backhoe attachment boom cylinder.

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Copyright © 102


BACKHOE ATTACHMENT BOOM CYLINDER DISASSEMBLY

1. Wiper ring 2. Bushing

11. O-ring

3. Cylinder rod

12. Piston gasket

4. Wiper ring

13. Piston guide

5. Seal ring

14. Piston

6. Ring

15. Screw

7. Guide bush

16. Cylinder tube

8. Screw

17. Bushing

9. Cylinder head

18. Wiper ring

10. Back-up ring


WARNING Cylinder weight (580T - 580ST): 92.7 kg (204.36 lb). Cylinder weight (590ST - 695ST): 106 kg (233.69 lb). Lift and securely place the cylinder on a workbench. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

Copyright © SECTION 35 - HYDRAULIC SYSTEM Support the cylinder rod (3). Unscrew and remove the safety screw (8). Use wrench 380000724 to loosen the cylinder head (9). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture.

Extract the cylinder head (9) from the cylinder barrel (16) by tapping it with a plastic hammer. Remove the cylinder rod (3) and the cylinder head (9). IMPORTANT: be sure to pull the cylinder rod (3) straight so as not to damage the sliding surfaces.


Only if necessary: - remove the wiper ring (4), the seal ring (5), the ring (6), the guide bush (7) and the back-up ring (10) with the O-ring (11) from the cylinder head (9); - remove the piston guide ring (13) and the piston seal (12) from the piston (14).

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BACKHOE ATTACHMENT DIPPER CYLINDER

1. Stroke

590ST - 695ST


BACKHOE ATTACHMENT DIPPER CYLINDER REMOVAL Move the machine to a level and firm ground. Place the bucket firmly on the ground. Support the backhoe attachment elements for cylinder removal using a suitable support.

WARNING Always support the structural members so that they will be stable and safe to work around. Stop the engine and move the backhoe attachment control levers through all operating positions to relieve any residual pressures in the system. Position a sling or other suitable lifting equipment around the cylinder.

580T - 580ST

Copyright © SECTION 35 - HYDRAULIC SYSTEM Check that the dipper (A) and the boom (B) are in a safe position to prevent involuntary movements after the removal of the dipper cylinder (1).

Remove the snap rings (2) and the spacers (3). Extract the pin (4) with a hammer.

Remove the snap rings (5) and the spacers (6). Slide out the rod pin (7) with an hammer. Remove the backhoe dipper cylinder.

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Copyright © 106


BACKHOE ATTACHMENT DIPPER CYLINDER DISASSEMBLY

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. Seal ring

14. Piston

6. Ring

15. Screw

7. Guide bush

16. Cylinder tube

8. Safety screw

17. Bushing

9. Cylinder head


WARNING Cylinder weight (580T - 580ST): 73.4 kg (161.82 lb). Cylinder weight (590T - 695ST): 74.6 kg (164.46 lb). Lift and securely place the cylinder on a workbench. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

Copyright © SECTION 35 - HYDRAULIC SYSTEM Support the cylinder rod (3). Unscrew and remove the safety screw (8). Loosen the cylinder head (9). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture.



Only if necessary: - remove the wiper ring (4), the seal ring (5), the ring (6), the guide bush (7) and the back-up ring (10) with the O-ring (11) from the cylinder head (9); - remove the piston guide ring (13) and the piston seal (12) from the piston (14).

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Copyright © 108


BACKHOE BUCKET CYLINDER

1. Stroke

580T - 580ST


BACKHOE BUCKET CYLINDER REMOVAL Move the machine to a level and firm ground. Place the bucket firmly on the ground.

WARNING Always support the structural members so that they will be stable and safe to work around. Stop the engine and move the backhoe attachment control levers through all operating positions to relieve any residual pressures in the system. Position a sling or other suitable lifting equipment around the cylinder. Remove the snap ring (1) and the spacer (2). Extract the pin (3) with a hammer and pay attention to bucket levers. If necessary use hydraulic power to very slowly retract the cylinder.

590ST - 695ST

Copyright © SECTION 35 - HYDRAULIC SYSTEM Disconnect the hoses (T). Cap or plug all exposed openings. Remove the snap ring (4) and the spacer (5). Extract the pin (6) with a hammer.

Remove the backhoe bucket.

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Copyright © 110


BACKHOE BUCKET CYLINDER DISASSEMBLY

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. Seal ring

14. Piston

6. Ring

15. Screw

7. Guide bush

16. Cylinder tube

8. Safety screw

17. Bushing

9. Cylinder head

18. Wiper ring


WARNING Cylinder weight (580T - 580ST): 60.7 kg (133.82 lb). Cylinder weight (590ST - 695ST): 67 kg (147.71 lb). Lift and securely place the cylinder on a workbench. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

Copyright © SECTION 35 - HYDRAULIC SYSTEM Support the cylinder rod (3). Unscrew and remove the safety screw (8). Loosen the cylinder head (9). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture.



Only if necessary: - remove the wiper ring (4), the seal ring (5), the ring (6), the guide bush (7) and the back-up ring (10) with the O-ring from the cylinder head (9); - remove the piston guide ring (13) and the piston seal (12) from the piston (14).

111

Copyright © 112


TELESCOPIC CYLINDER

1.

Stroke


580T - 580ST 590ST - 695ST

Copyright © SECTION 35 - HYDRAULIC SYSTEM TELESCOPIC CYLINDER DISASSEMBLY

1. Cylinder rod

9. Back-up ring

2. Bushing

10. O-ring

3. Wiper ring

11. Piston

4. Ring

12. Piston gasket

5. Seal ring

13. Piston guide

6. Guide bush

14. Screw

7. Cylinder head

15. Cylinder tube

8. Safety screw

16. Bushing


WARNING Cylinder weight (580T - 580ST): 37.6 kg (82.90 lb). Cylinder weight (590ST - 695ST): 41.9 kg (92.37 lb). Lift and securely place the cylinder on a workbench. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

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Copyright © 114


Support the cylinder rod (1). Unscrew and remove the safety screw (8). Loosen the cylinder head (7). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture.



Only if necessary: - remove the wiper ring (2), the seal ring (3), the ring (4), the guide bush (5) and the O-ring (9) with the back-up ring (8) from the cylinder head (7); - remove the piston guide ring (11) and the piston seal (10) from the piston (12).

Copyright © SECTION 35 - HYDRAULIC SYSTEM STABILIZER CYLINDER - CENTER PIVOT (695ST)

(1) Stroke (2) Completely retracted

STABILIZER CYLINDER REMOVAL - CENTER PIVOT Make sure that the backhoe loader is locked in the transfer position or parked in a safety work position. Lower the stabilizers to the ground.

Support the cylinder safely with suitable belt and hoist. Remove the snap ring (1) and the shim (2). Extract the pin (3) with a hammer. Using the hydraulic power, retract the cylinder very slowly.

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Copyright © 116


Stop the engine. Release possible residual pressure by moving the control levers of the stabilizers. Disconnect all hoses. Cap or plug all exposed openings. Remove the snap ring (4) and the shim (5). Hammer to slide out the pin (6).

Remove the stabilizer cylinder.

Copyright © SECTION 35 - HYDRAULIC SYSTEM STABILIZER CYLINDER DISASSEMBLY - CENTER PIVOT

1. Cylinder rod

8. Back-up ring

2. Wiper ring

9. O-ring

3. Ring

10. Piston gasket

4. Seal ring

11. Piston guide

5. Guide bush

12. Piston

6. Safety screw

13. Screw

7. Cylinder head

14. Cylinder tube


WARNING Cylinder weight: 43.4 kg (95.68 lb). Lift and securely place the cylinder on a workbench. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

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Copyright © 118


Replace the cylinder rod (1). Unscrew and remove the safety screw (6). Use wrench 380000726 to loosen the cylinder head (7). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture.



Only if necessary: - remove the wiper ring (2), the seal ring (3), the ring (4), the guide bush (5) and the O-ring (9) with the back-up ring (8) from the cylinder head (7); - remove the piston guide ring (11) and the piston seal (10) from the piston (12).

Copyright © SECTION 35 - HYDRAULIC SYSTEM STABILIZER CYLINDER - SIDESHIFT


STABILIZER CYLINDER REMOVAL - SIDESHIFT Move the machine to a level and firm ground. Place the bucket firmly 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. Loosen and remove the screw (1) and the nut (2). Extract the pin (3) to release the cylinder rod.

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Copyright © 120


Disconnect the hydraulic tubes at the top of the stabilizer leg. Remove the snap ring (4) and extract the pin (5). Screw in an eye screw (6) on the cylinder and connect a rope or a chain.

Lift and remove the stabilizer cylinder.

Copyright © SECTION 35 - HYDRAULIC SYSTEM STABILIZER CYLINDER DISASSEMBLY - SIDESHIFT

1. Cylinder rod

8. Back-up ring

2. Wiper ring

9. O-ring

3. Seal ring

10. Piston

4. Ring

11. Piston guide

5. Guide bush

12. Piston gasket

6. Cylinder head

13. Screw

7. Safety screw

14. Cylinder tube


WARNING Cylinder weight: 34.6 kg (76.28 lb). Lift and place the cylinder on a workbench and secure it to a vice. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

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Copyright © 122


Support the cylinder rod (1). Unscrew and remove the safety screw (6). Use wrench 380000721 to loosen the cylinder head (7). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture.



Only if necessary: - remove the wiper ring (2), the seal rings (3), the ring (4), the guide bush (5) and the O-ring (9) with the back-up ring (8) from the cylinder head (7); - remove the piston guide ring (11) and the piston seal (10) from the piston (12).

Copyright © SECTION 35 - HYDRAULIC SYSTEM SWING CYLINDER


SWING CYLINDER REMOVAL Move the machine to a level and firm ground. Place the bucket firmly on the ground. Support the backhoe attachment elements for cylinder removal using a suitable stand and a hoist.

WARNING Always support the structural members so that they will be stable and safe to work around. Stop the engine and move the backhoe attachment control levers through all operating positions to relieve any residual pressures in the system. Loosen and remove the nut (1). Slide out the screw (2) from the opposite side. Now the pin (3) can come out and release the rod cylinder. If necessary hammer to help the pin (3) to come out.

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Disconnect the feed and return hose to the cylinders and cap all exposed openings. Loosen and remove the nuts (4) and the screws (5) (from both sides). Now it is possible to remove the support (6).

Carefully lift and remove the swing cylinder.

Copyright © SECTION 35 - HYDRAULIC SYSTEM SWING CYLINDER DISASSEMBLY

1. Bushing

10. King pin

2. Wiper ring

11. O-ring

3. Cylinder rod

12. Back-up ring

4. Wiper ring

13. Piston gasket

5. Seal ring

14. Piston guide

6. Ring

15. Piston

7. Guide bush

16. Lock retaining piston

8. Bushing

17. Cylinder tube

9. Seal ring


WARNING Cylinder weight: 31 kg (68.34 lb). Lift and place the cylinder on a workbench and secure it to a vice. Be sure that the cylinder is placed horizontally. Drain hydraulic oil from the cylinder.

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Use the wrench 380000725 to loosen the king pin (10). If necessary gently heat the gland carrier to soften the thread sealant applied during manufacture. Remove the rod assy with the king pin and the piston assy.

Unscrew and remove the piston lock (16). Disassemble the cylinder rod (3) and piston assy (15) and the king pin (10) complete with gaskets. Check the bushings (8) status.

Only if necessary: - remove the wiper ring (4), the seal ring (5), the ring (6), the guide bush (7) and the back-up ring (12) with the O-ring (11) from the king pin (10). - remove the piston seal (13) and the piston guide ring (14) from the piston (15).

Copyright © SECTION 35 - HYDRAULIC SYSTEM BACKHOE ATTACHMENT LOCK CYLINDER - SIDESHIFT 4 sideshift locking cylinders are installed on the backhoe loader. Their function is to lock the carriage once the backhoe attachment is in digging position. The cylinder consists of: 1. Body 2. Cylinder 3. Gasket

BACKHOE ATTACHMENT LOCK CYLINDER REMOVAL Park the machine on a flat surface and position the bucket on the ground. Position the backhoe support in the centre of the machine and lower the backhoe on the ground. Lower the stabilizers to the ground. Relieve the residual pressure in the system by moving the control levers through all operating positions.

Disconnect the line (1). Loosen and remove the two screws (2). Now it is possible to remove the whole cylinder (3).

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DESCRIPTION

380000721

Wrench

380000722

Wrench

380000724

Wrench

APPLICATION Telescopic dipper cylinder head Stabilizer cylinder head (sideshift) Loader bucket cylinder head Backhoe boom cylinder head Backhoe dipper cylinder head Backhoe bucket cylinder head

380000725

Wrench

Swing cylinder head Loader cylinder head

380000726

Wrench

Stabilizer cylinder head (center pivot)


129

HYDRAULIC CONTROL LEVERS TECHNICAL SPECIFICATIONS Weight

5.1 ÷ 5.3 kg (11.24 ÷ 11.68 lb)

Spool stroke

7.55 mm (0.29 in) SPECIAL TORQUE SETTINGS

Maximum permissible on the hydraulic control lever

80 Nm (59 lbf·ft)

Control block retaining screw

30 Nm (22 lbf·ft)

Control block cardan joint

50 Nm (37 lbf·ft)

Control block nut

40 Nm (30 lbf·ft)

Lower body screw

50 Nm (37 lbf·ft)

Copyright © 130


CONTROLS AND OPERATION

1. CONTROL ENABLE SWITCH: when set to ON (control lamp on), this switch allows enabling all hydraulic controls of the backhoe attachment. 2. LEFT HAND HYDRAULIC CONTROL LEVER: the left-hand hydraulic control lever controls attachment swing and the boom or the dipper (depending on the control pattern adopted).

6. TELESCOPIC DIPPER CONTROLS: (proportional controls): press the right-hand button to extend the telescopic dipper. Press the left-hand button to retract the telescopic dipper. 7. WRIST RESTS: the wrist rests may be adjusted to the required height.

3. RIGHT HAND HYDRAULIC CONTROL LEVER: the right-hand hydraulic control lever controls the bucket and the boom or the dipper (depending on the control pattern adopted).

8. HYDRAULIC CONTROL LEVER SUPPORT ANGLE ADJUSTMENT: these controls are used for the fore/aft and left/right adjustment of the arm.

NOTE: the operating speed depends on the angle of movement of the control levers. In intermediate position, two movements may be obtained simultaneously.

9. HORN BUTTON: (momentary action control).

4. STABILIZER CONTROLS: the right-hand control is for the right-hand stabilizer and the lefthand control is for the left-hand stabilizer.

11. DECELERATOR BUTTON: by pressing this button, the engine rpm sets to low idle. During this phase, the accelerator knob and pedal are disabled. By pressing the button again, the engine rpm is restored and the accelerator knob and pedal are functional again.

5. CONTROL PATTERN CHANGE SWITCH: this switch is used for changing the standard control pattern to the ISO pattern.

10. CONTROLS OF AUXILIARY BIDIRECTIONAL ATTACHMENT (If fitted): proportional buttons for the activation of the additional attachment.

Copyright © SECTION 35 - HYDRAULIC SYSTEM COMPONENTS 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. Clip

8. Half handle

17. Plugs [if the switches (12) are not fitted]

9. Screw

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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. Plugs [if the switches (18) are not fitted]

8. Half handle

18. Push-buttons (auxiliary bidirectional)

9. Screw

19. Connector

10. Half handle

20. Wedge

Copyright © SECTION 35 - HYDRAULIC SYSTEM DISASSEMBLY AND ASSEMBLY Disassembly Release the pressure from the hydraulic systems by carrying out the operations described below. Turn the starter switch key to ON but do not start the engine. Turn pilot control cancellation switch to the ON position. Move the hydraulic control levers through all positions. Turn the starter switch key to OFF. Disconnect the negative battery cables. Mark the position of the lever parts (see the exploded view on previous pages). Remove the knob (P) and the support (S). Remove the bracket (O) with the relevant screws (with left hydraulic control lever).

Remove the decal (D), the mounting plate (D1) and the detach the connectors (Q) (with left hydraulic control lever).

Pull out both switches (I) and the detach relevant connectors (Q1) (with right control lever).

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Copyright © 134


Remove the knob (P1) in the rear section of control lever.

Remove the screws (V) and the plate (N).

Lift the rubber boot (RL) for left control lever and the rubber boot (RR) for right control lever.

Tag all hydraulic hoses before disconnecting them. Disconnect all hoses (H). Disconnect all connectors (Q2).

Copyright © SECTION 35 - HYDRAULIC SYSTEM - Remove the screws (V1) and take out control lever from the column.

Remove the screws (9). Remove the half handles (8) and (10). Remove the cap (11). Remove the wedge (7) from the connector (6). Remove the wedge (20) from the connector (19). Remove the discs (6) and (19). Remove the grommet (13), the clips (15) and the tie hose (16). Extract the switches (12) and (18). Remove the spacers (14). Remove the boots (5). Loosen the nut (4) and remove the screw (3). Remove the plate (2).

Assembly Proceed in reverse order. Follow the marks made during disassembly and tighten the nut (4) to a torque of 36 ÷ 44 Nm (26 ÷ 32 lbf·ft).

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Copyright © 136


CONTROL LEVER VALVE P. Supply T. Return to tank Right valve (dipper/bucket) 1. Retracting the dipper 2. Opening the backhoe bucket 3. Extending the dipper 4. Closing the backhoe bucket Left valve (backhoe attachment/swing) 1. Boom 2. Right swinging 3. Lowering 4. Left swinging

1. cardan joint cam 2. Plate 3. Shim 4. Upper body 5. Rod guide 6. Seal ring 7. Seal ring 8. Rod 9. Spring guide 10. Spring 11. Shim 12. Cover 13. Safety ring 14. Spring 15. Spool 16. Shims 17. Valve 18. O-ring 19. Lower body 20. O-ring 21. O-ring

Copyright © SECTION 35 - HYDRAULIC SYSTEM HYDRAULIC CONTROL LEVER VALVE OVERHAUL Disassembly Mark the direction of installation of all disassembled parts. Remove the U/J cam (1) using a key. Remove the plate (2). Remove the shim (3) from the upper body (4). Extract the rod guide (5) and replace the seal rings (6) and (7). Drift the rod (8) out. Remove the spring guide (9), the spring (10) and the shims (11). Extract the spool assembly. Hold the cover (12) and remove the safety ring (13). Remove the spring (14) and the spool (15). Remove and note the thickness of the shims (16). Proceed in the same manner for the other rods. Secure the upper body (4) in a vice. Loosen and remove the screw (17) using a key and replace the O-ring (18). Separate the upper (4) and lower (19) bodies and replace the seal rings (20) and (21). Assembly To reassemble, proceed in the reverse order to that of removal. In the case of reassembly without changing the U/J cam (1), put the same value of shims (3) as those in place. After changing the U/J cam (1) adjust the pressure of the cam on the rods. Install a 2 mm (0.079 in) shim (3), check that the recessing of the push-rods is less than 0.2 mm (0.009 in), modify the shimming to more or less if required. Assemble the new seal rings (6), (7) and O-rings (18), (20) and (21). Lubricate the moving parts. Apply brake thread fluid on the threads of the U/J cam (1) and the screw (17). Tighten the cam (1) and the screw (17) to a tightening torque of 50 Nm (37 lbf·ft).

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Copyright © 138


TROUBLESHOOTING PRELIMINARY CHECKS When troubleshooting, the pressure and flow rate test must be carried out in a systematic manner and the results analyzed.

The above-described preliminary checks assume that the failure is not linked to the engine performance.

In this way, the trouble may be identified immediately and accurately.

Having performed these checks and failed to locate the cause of the malfunction, the following procedures should be adopted:

If short-cuts, assumptions and guesses are made, unnecessary component disassembly or replacement could result. Follow the step-by-step procedures outlined below. As a first step in the fault finding procedure, several preliminary checks should be made. These checks are important because, once they have been performed, they need no longer be considered as a possible cause of the immediate or reported malfunction. Check that the hydraulic oil is at the correct level and of the correct specification. Check the loader, backhoe or any additional accessory such as hydraulic bucket, hammers etc., for correct assembly or installation and additionally for signs of external damage that might cause gross misalignment of structural members. Check in more detail for other mechanical damage such as kinked, twisted, worn or decayed hoses, damaged cylinders and bent elements. Do not forget to check underneath the unit for damaged steel tubes, particularly if the unit has been known to have operated in arduous conditions, been grounded, or bogged down. Ensure optimum operating temperature of the hydraulic oil is achieved. Perform the system pressure and rear pump relief valve pressure tests.

- if possible, operate the backhoe attachment and make notes of its operating characteristics. Move each cylinder control lever so that the cylinders move from the fully extended to the fully retracted position; - compare the operating characteristics in the preceding stage with the malfunctions listed hereunder.


139

TROUBLESHOOTING (WITH “REXROTH” CONTROL VALVES) GENERAL TROUBLE All systems fail to operate.

Slow operation or loss of power in all systems.

CAUSE

ACTION

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.

Worn pump

Perform pump performance test and replace/reseal as necessary.

Restricted pump suction line.

Inspect the suction line and the tank and repair as necessary.

Load sensing pressure relief valve incorrectly adjusted.

Make a system pressure test.

Hydraulic speed solenoid valve inoperative.

Make a system pressure test.

CAUSE Valve spool leaking.

ACTION Examine lift section of loader control valve assembly for wear or scoring. Examine/reseal piston and gland.

LOADER ATTACHMENT TROUBLE The lifting system fails to operate, is slow or loses power. The bucket fails to operate, is slow or loses power.

Cylinder leak (spools in neutral).

Hesitation in the raising movement of the loader attachment or of the bucket cylinders when the control is initially actuated.

Piston seals leaking or cylinder barrel damaged. The relief valves are stuck open, set to a too low value or there is a leak in the seat. Valve spool leaking.

Piston seals leaking or cylinder barrel damage. Damaged piston barrel. Internal valve leak.

Load check valve between control valve sections damaged.

Check the bucket system relief valve.

Examine bucket section of loader control valve assembly for wear or scoring. Examine/reseal piston and gland. Examine/reseal piston and gland. Examine appropriate valve section of loader control valve assembly for wear or scoring. Disassemble and inspect.

Copyright © 140


BACKHOE Refer to the following backhoe fault finding chart after first considering the preceding charts. This chart should only be referred to if the supply system is operating normally, thereby confirming that the hydraulic supply systems and the pump are correctly operating. See also “Fault finding hydraulic pump”. TROUBLE The lifting system is inoperative, is too slow, loses power or does not hold.

The digging control fails to operate, is slow or loses power.

The digging control fails to operate, is slow or loses power.

The telescopic dipper fails to operate, is slow or loses power.

Stabilizer pads leaking.

CAUSE

ACTION

Lifting system relief valve stuck open, set too low or seat leaking.

Test the pressure of the lifting system relief valve.

Valve spool leaking.

Examine lift section of backhoe control valve assembly for wear and scoring.

Piston seals leaking or cylinder barrel damaged.

Examine/reseal piston and gland.

Digging system relief valve (piston end) stuck open, set too low or seat leaking.

Test the pressure of the digging system relief valve.


Examine digging section of backhoe control valve assembly for wear and scoring.



The bucket relief valve (rod end) is stuck open, set to a too low value or there is a leak in the seat.

Test the pressure of the bucket relief valve.


Examine bucket section of backhoe control valve assembly for wear and scoring.



The telescopic dipper system relief valve (piston end) is stuck open, set to a too low value or there is a leak in the seat.

Test the pressure of the telescopic dipper relief valve.


Examine telescopic dipper section of backhoe control valve assembly for wear and scoring.



Stabilizer lock valve leaking.

Inspect/overhaul the stabilizer lock valve.




141

SWING TROUBLE Right or left swing is inoperative, is too slow or loses power.

CAUSE

ACTION

Swing system relief valves not seating, set too low or seat leaking.

Test the swing system relief valve.


Examine swing section of backhoe control valve assembly for wear or scoring.



The swing fails to slow down (bearing stop) at stroke end.

Built-in sliding limiter damaged.

Disassemble and inspect.

Piston seals leaking or cylinder barrel damage.


The swing does not stop when the control lever returns to neutral (one direction only).

The system relief valve (return side) is stuck open, set to a too low value or there is a leak in the seat.

Test the swing system relief valve.


Examine swing section of backhoe control valve assembly for wear or scoring.

Cylinder leak (spools in neutral).

Internal valve leak.

Examine appropriate valve section of backhoe control valve assembly for wear or scoring.



Load check valve between control valve sections damaged.

Disassemble and inspect.

A system temporarily lowers when given the control to lift.

Copyright © 142


HYDRAULIC PUMP TROUBLE Noisy system.

Hydraulic oil drain through tank breather.

Oil heating.

CAUSE

ACTION

Worn or damaged pump gears or pressure plates.

Make a hydraulic pump performance test.

Aeration: air entering the systems at: suction tube, pump shaft, fittings or cylinder ring nuts.


Cavitation: system restrictions in the suction line or in the tank filter.

Make a visual check and/or a hydraulic pump performance test.

Water in the system.

Visual check.

The system relief valve vibrates.

Check system relief valve, adjust/ overhaul as necessary.

Vibrations in the lines.

Visual check.

Cold hydraulic oil.

Check the hydraulic oil operating temperature.

Wrong oil type.

Investigate/drain and top up.

Tank overfilled.

Check the hydraulic oil level.

Aeration: air entering the system at: suction tube, pump shaft, fittings or cylinder ring nuts.


Cavitation: Restriction of the suction filter in the tank.

Make a visual check and/or a hydraulic pump performance test.

Low oil quantity.

Fill the tank.

Contaminated oil.

Drain the tank and refill with clean oil.

Too high/low setting of the relief valve. Drain the tank and refill with clean oil. Test relief valves. Oil in system too light.

Drain the tank and refill with oil with the correct viscosity.

Oil cooler fins obstructed.

Clean the oil cooler.

Oil leaks through the shaft seal.

Worn shaft seal.

Replace shaft seal and inspect pump.

Foamy oil.

Low oil level.

Fill the tank.

Air in the suction system.

Check/tighten suction line.

Wrong oil type.

Drain and refill with correct oil.

Copyright ©

580T 580ST 590ST 695ST

SECTION 39 - CHASSIS DESCRIPTION ................................................................................................................................................. 3 REMOVAL AND INSTALLATION OF COMPONENTS .................................................................................... 5 COMPONENTS WITHIN THE CHASSIS .................................................................................................... 5 COMPONENTS OF THE LOWER PART OF THE CHASSIS ..................................................................... 6 COMPONENTS ATTACHED OUTSIDE THE CHASSIS........................................................................... 10 COMPONENTS OF THE UPPER PART ................................................................................................... 11

Copyright © 2

SECTION 39 - CHASSIS

Copyright © SECTION 39 - CHASSIS

DESCRIPTION The chassis of the Backhoe Loader is manufactured as a one-piece unit, on which the main assemblies are attached, or which supports the main assemblies. TYPES Some kinds of chassis are available, which differ from each other according to some main characteristics of the Backhoe Loader. Backhoe attachment: - Center pivot (fixed central rotation) (only 695ST): the backhoe attachment is directly connected to the chassis and cannot shift laterally; - Sideshift: the backhoe attachment is installed on a sideshift support and can shift laterally on the chassis guides. Steering: - 2 wheel steering (2WS); - 4 wheel steering (4WS).

3

Copyright © 4 2WS SIDESHIFT CHASSIS

4WS SIDESHIFT CHASSIS

4WS CENTER PIVOT CHASSIS


Copyright © SECTION 39 - CHASSIS

5

REMOVAL AND INSTALLATION OF COMPONENTS COMPONENTS WITHIN THE CHASSIS

ENGINE Supported by 2 rubber silent blocks and held in position by 2 support brackets.

Remove:

The brackets are welded to the frame on either side of the engine.

- the engine guard;

WARNING Since they are fastened to each other, the engine and the transmission operate as a one-piece unit. If separated in the machine they are not self supporting and will collapse causing injury or damage to the machine. TRANSMISSION Attached to the rear side of the engine and supported by means of brackets provided with rubber silent blocks. To make repairs that require disassembly of the transmission or engine it will be necessary to remove the engine/transmission as a complete unit from the chassis. To remove the engine/transmission from the machine, it will be necessary to carry out some operations.

- the air filter; - the radiator and the relevant hoses (or pivot it forwards if possible); - the front support grid (if necessary). Disconnect: - the cable for supply pump throttle and electric shut-off; - the engine wiring harness; - the fuel tank connection and the recovery/return hoses; - the relevant hoses (plug all ports as required) of the hydraulic pump; - the transmission lever; - the transmission wiring harness connectors.

Copyright © 6


COMPONENTS OF THE LOWER PART OF THE CHASSIS

FRONT AXLE The front axle is attached to the underside of the chassis by 6 through screws (2WS) or 4 through screws (4WS). To remove front axle from the machine see “REMOVAL FROM MACHINE” in SECTION 25 FRONT AXLE.

REAR AXLE The rear axle is attached to the frame at the rear of the machine by 4 through screws. To remove rear axle from the machine see “REMOVAL FROM MACHINE” in SECTION 27 REAR AXLE.

Copyright © SECTION 39 - CHASSIS CARDAN SHAFTS 2WS

1. Front axle 2. Front cardan shaft 3. Screw [tightening torque 33 ÷ 39 Nm (24 ÷ 29 lbf·ft)] 4. Bracket 5. Bracket 6. Screw [tightening torque 35 ÷ 41 Nm (26 ÷ 30 lbf·ft)] 7. Rear cardan shaft 8. Rear axle

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Copyright © 8


4WS

1. Front axle 2. Bracket 3. Screw [tightening torque 35 ÷ 41 Nm (26 ÷ 30 lbf·ft)] 4. Front cardan shaft 5. Bracket 6. Screw [tightening torque 35 ÷ 41 Nm (26 ÷ 30 lbf·ft)] 7. Rear cardan shaft 8. Rear axle

Copyright © SECTION 39 - CHASSIS COUNTERWEIGHT

It is installed under the chassis in the front section of the machine. There are different types of counterweights: 2WS (A): 1. Standard counterweight .............159 kg (350 lb) 2. Medium counterweight...............330 kg (727 lb)

4WS (B): 3. Standard counterweight .............160 kg (352 lb)

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Copyright © 10


COMPONENTS ATTACHED OUTSIDE THE CHASSIS

TANKS The hydraulic oil tank (1) and the fuel tank (2) are attached to the chassis under the cab, respectively to the right-hand and left-hand side of the machine. When drained of their contents, both tanks can be removed from the machine, disconnecting the relevant hoses and removing the fastening screws [tightening torque of 85 Nm (63 lbf·ft)]. IMPORTANT: make sure that all inlets and pipes are plugged or blanked off to prevent the dirt from entering them.

Copyright © SECTION 39 - CHASSIS COMPONENTS OF THE UPPER PART CAB

A. Front coupler

6. Nut

B. Rear coupler

7. Retaining screw

C. Cab skirts

8. Washer

1. Main frame

9. Cab floor

2. Anti-vibration

10. Cab support (rear)

3. Dampener

11. Support

4. Washer

12. Bushing

5. Washer

13. Cab support (front)

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Copyright © 12


The cab frame is a one-piece unit, mounted on top of the chassis. To remove the cab it is necessary to carry out different operations, listed below. Remove the cab skirts (S) all around the cab. Disconnect the two electric connectors from the main harness and engine harness. Remove the two front fixing screws (7) between the cab floor and the cab support (13) (detail A). Remove the two rear fixing screws (7) between the cab floor and the rear supports (10) on the main frame (1) (detail B). Disconnect the two steering cylinder hoses (left side). Disconnect the pump - power steering valve hose. Disconnect the power steering valve - oil tank hose. Disconnect the load sensing valve hose. Disconnect the stabilizer cables (mechanical version). Disconnect the parking brake cable. Disconnect the water - heater hoses (after water discharge). Disconnect the air conditioning hoses (after coolant drain). Disconnect the transport lock cable (mechanical version). Disconnect the telescopic dipper control pedal (mechanical version). Turn the knobs and the boots of the various levers (front and rear) Lift the cab with the crane after its anchorage to lifting hook. IMPORTANT: when lifting the cab ensure the hydraulic brake tanks are not caught and damaged on the loader support frame.

Copyright ©

580T 580ST 590ST 695ST

SECTION 41 - STEERING SYSTEM DESCRIPTION ................................................................................................................................................. 3 2WS STEERING SYSTEM ............................................................................................................................... 4 4WS STEERING SYSTEM ............................................................................................................................... 7 POWER STEERING ....................................................................................................................................... 11 TECHNICAL SPECIFICATIONS................................................................................................................ 11 COMPONENTS ......................................................................................................................................... 13 DISASSEMBLY.......................................................................................................................................... 15 ASSEMBLY................................................................................................................................................ 18

Copyright © 2

SECTION 41 - STEERING SYSTEM

Copyright © SECTION 41 - STEERING SYSTEM

DESCRIPTION The steering system has the following features: - double-acting steering cylinder; - oil tank in common with the main hydraulic system; - a hydraulic pump located on the rear part of the transmission; - steering (or power steering) control valve located on the steering wheel’s column. The oil is taken from the tank and reaches the pump. The front pump flow is directed to the loader and backhoe attachment control valves. Thanks to the presence of a flow divider, the rear pump delivery guarantees priority oil delivery to the steering system. The flow divider includes a load-sensing valve and a steering system pressure relief valve. According to the machine model, the steering system can be of 2 types: - 2WS steering system; - 4WS steering system.

3

Copyright © 4


2WS STEERING SYSTEM

1. Flow divider

5. Oil filter

2. Power steering

6. By-pass valve

3. Hydraulic tank

7. Radiator

4. Return manifold

8. Front axle

Copyright © SECTION 41 - STEERING SYSTEM OPERATION Power steering - Neutral position

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 neutral position. This ensures that no more oil is supplied to the steering cylinder. The spool also traps the oil in the steering cylinder and allows the oil in the sensing lines to return to the tank, thus allowing the priority flow divider to move to the left.

5

Copyright © 6


Power steering - Turning right

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 passages. During right turn, oil flows through the spool along a groove and into a passage in the housing which leads to the metering unit. A gallery is also lined up to allow pressure oil to flow down the sensing line to the priority flow divider.

As the metering unit is turned by the drive shaft, it directs a measured quantity of oil along another set of passages in the spool then from these to the steering cylinder. Return oil from the other side of the cylinder is directed through the spool to a return passage in the housing.


4WS STEERING SYSTEM

1. Flow divider

6. By-pass valve

2. Power steering

7. Radiator

3. Hydraulic tank

8. Front axle

4. Return manifold

9. 4WS steering control valve

5. Oil filter

10. Rear axle

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Copyright © 8


4WS STEERING CONTROL VALVE The valve is located on the rear axle. Remove the four hoses and the two fastening screws. Remove the valve. Draw a diagonal line across the complete valve block this will assist in the correct reassembly later. The valve consists of a central manifold block which all input and output pipes are attached to. On each side of this block is a solenoid valve. The solenoid valves have two positions: both of these positions are working positions and there is no neutral point. Each spool is detented and therefore the solenoids are only energized momentarily to move the spool. On the end of each solenoid is an emergency hand operating pin which moves the control spool without energizing the solenoid. The switching of the steering valve is normally controlled by a microprocessor located underneath the right hand side console. Components 1. Solenoid knob 2. Solenoid 3. Control spool 4. Block 5. Central block 6. Fixing screws 7. Piston 8. O-ring 9. O-ring

Copyright © SECTION 41 - STEERING SYSTEM OPERATION

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.

9

Copyright © 10


The spool in valve (3) was last moved by solenoid (3b): oil flowing in from P3 flows through the internal galleries of the spool and exits at port A3. From here, oil enters valve (2), whose spool was last moved by solenoid (2b). Oil flows through port P2 and exits through port T2, cutting off flow to the rear steering cylinder. Now the oil returns in valve (3), entering through port B3 and flowing out through port T3. From here, oil enters the front steering cylinder.

The three modes of steering are as follows: Front wheel only steering

Front and rear wheel steer

Front and rear wheel crab The solenoids energized are shown in the table below. These are also the pins which need to be pressed when changing steering mode manually in an emergency. X = Energized O = Not Energized 3a

3b

2a

2b

2WS

O

X

O

X

2WS

X

O

O

X

4WS

O

X

X

O

CRAB

X

O

X

O


POWER STEERING The power steering consists of a metering and emergency pump that includes: - a gearwheel with fixed stator with inner teeth and a rotor with outer teeth; - a 4-way rotary control valve consisting of an outer sleeve and an inner selection rotor; - a rotor connected to the steering wheel by means of the steering column, which can be of two types, fixed or adjustable; - a cardan shaft which is mechanically tied to the gearwheel and to the outer sleeve, and allows the transmission’s movement; - a set of centering springs between the outer sleeve and the inner rotor.

TECHNICAL SPECIFICATIONS L. Left control port (steering cylinder) R. Right control port (steering cylinder) P. Inlet to steering pump T. Outlet to oil tank LS. Outlet to steering pump

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Copyright © 12


2WS (with variable-flow-rate pump) Model ........................................................................................................................ EATON P/N 403 -8754-04 Displacement ............................................................................................................. 160 cm3/rev (9.76 in3/rev) Shock valve adjustment ......................................................................................................... 235 bar (3408 psi) Load-sensing pressure relief valve adjustment...................................................................... 175 bar (2538 psi) 2WS (with gear pump) Model ........................................................................................................................ EATON P/N 403 -8754-08 Displacement ............................................................................................................. 160 cm3/rev (9.76 in3/rev) Shock valve adjustment ......................................................................................................... 235 bar (3408 psi) Load-sensing pressure relief valve adjustment...............................................................................................No 4WS Model ........................................................................................................................ EATON P/N 403 -7754-04 Displacement ............................................................................................................. 160 cm3/rev (9.76 in3/rev) Shock valve adjustment ......................................................................................................... 235 bar (3408 psi) Load-sensing pressure relief valve adjustment...................................................................... 175 bar (2538 psi)

Copyright © SECTION 41 - STEERING SYSTEM COMPONENTS

13

Copyright © 14


A. Anticavitation valve

19. Seal ring

B. Manual check valve

20. Gasket

C. Inlet check valve

21. O-ring

D. Cylinder relief valve

22. Seal

E. Load-sensing relief valve

23. Bearing cup

F. Inlet relief valve

24. Bearing

1. Screw

25. Bearing cup

2. Cover

26. Spring

3. O-ring

27. Spacer

4. Spring

28. Sleeve

5. Plug

29. Plug

6. Ball

30. O-ring

7. Rotor/stator gear

31. Spring

8. Plate

32. Poppet

9. Shaft

33. O-ring

10. Power steering unit

34. O-ring

11. Valve seat

35. Ball

12. Ball

36. Pin

13. Ball holder

37. Spacer

14. O-ring

38. Valve seat

15. Spring

39. Poppet

16. Plug

40. Spring

17. Cross pin

41. O-ring

18. Spool

42. Plug

Copyright © SECTION 41 - STEERING SYSTEM DISASSEMBLY Cleanliness is extremely important when repairing the power steering. Work in a clean area. Before disconnecting the lines, thoroughly clean the area. Use a wire brush to remove foreign material and debris. Use protective material on vice jaws. Power steering unit distortion can result if jaws are over-tightened. M = mark

Loosen and remove the screws (1). Remove the cap (2). Remove the O-ring (3).

Remove the rotor / stator gear (7). Remove the O-ring (34). Remove the spacer (37).

15

Copyright © 16


Remove the shaft (9). Remove the plate (8). Remove the O-ring (33) from the power steering unit (10).

Carefully remove the anti-cavitation valve (A) and the manual check valve (B) from the holes of the screws by tipping.

Carefully remove the spool-sleeve (18) assembly from the power steering unit (10), keeping it vertical. Extract the pin (17) from the spool (18) and sleeve (28) assembly.

CAUTION Do not lift the spool-sleeve assembly inside the power steering unit (10). Slowly rotate the spool-sleeve assembly to remove it from the power steering unit.

Remove the bearing race (25), the bearing (24) and the bearing race (23) from the power steering unit (10). Remove the seal ring (19).

Copyright © SECTION 41 - STEERING SYSTEM Partially push the spool (18) on the end of the sleeve, then carefully remove the centering springs (26) from the spool (18). The power steering with low input torque uses four centering springs (26) and two spacers (27). The standard input torque power steering uses six centering springs. M = mark S1 = low torque springs S2 = standard springs NOTE: do not remove any valves other than the manual check valve and the anti-cavitation valves. All other valves are factory preset and are non-serviceable.

17

Copyright © 18


ASSEMBLY Check all mating surfaces. If any parts have scratches or burrs, the power steering must be replaced. The use of parts with scratches or burrs can cause leakage and is therefore not recommended. Clean all metal parts in clean solvent. Blow dry with air. Do not wipe dry with cloth or paper towel because lint or other matter can get into the hydraulic system and cause damage. Do not use grit paper or file or grind these parts. Lubricate all seals, replace all old seals with new seals and do not use an excessive quantity of lubricant on the seals of the rotor / stator gear. Carefully assemble the spool (18) and the sleeve (28) so that spring slots line up correctly. Rotate spool while sliding parts together. M = marks Test for free rotation. The spool should rotate smoothly in the sleeve with finger tip force applied to its end. Align the spool and the sleeve making reference to the relevant marks (M).

The centering springs (26) for power steering with low input torque (S1) have four arched springs with two flat spacers (27) in the center. The centering springs (26) for power steering with standard input torque (S2) have six arched springs. Position centering springs so that the notches line up, and arched center sections are nested together. Next, with spring notches facing sleeve, insert one end of entire spring set into spring installation tool.

Copyright © SECTION 41 - STEERING SYSTEM Compress the extended end of the spring set and push it into the spool (18) - sleeve (28) assembly. Keep pressure on spring ends while withdrawing installation tool and pushing forward on springs at same time. Central springs set in spring slots. Seat springs down evenly and flush with upper surface of spool (28) and sleeve (18).

Insert the pin (17) through the spool (18) - sleeve (28) assembly until the pin is within the outside diameter of the sleeve.

Lubricate the seal ring (19). Install the bearing races (23), (25) and the bearing (24).

19

Copyright © 20


Position the spool (18) - sleeve (28) assembly so that the splined end of the spool enters the power steering body first.

CAUTION While inserting the spool-sleeve assembly, make sure that the parts do not tilt out of position. Gently push the assembly into place with a slight rotation, holding the pin so that it does not come out and gets stuck in the internal groove. Completely insert the spool-sleeve assembly into the body. With aligned spool-sleeve assembly, check for free rotation by turning the assembly with fingertip force applied to the end. Position the power steering unit (10) in a vice. Lightly clamp on the edges of the mounting area; do not over-tighten the jaws. NOTE: make sure that the spool and the sleeve are flush or slightly below the unit’s surface. Clean the upper surface of the unit.

Install the O-ring (33). Install the anti-cavitation valves (A) and the manual check valve (B). Install the plate (8). Align the holes in the plate (8) with the threaded holes in the unit (10).

Copyright © SECTION 41 - STEERING SYSTEM Rotate the spool and sleeve assembly until the pin is parallel with the port’s face. Install the shaft (9), making sure it is engaged with pin (17). To guarantee proper alignment, mark the shaft (see reference L2). When marking the shaft, note the relationship between slotted end and splined end. Lubricate and install the O-ring (34). The lubrication will hold the seal in place. Note the parallel relationship of reference lines L1, L2, L3 and L4. Lubricate and install the O-ring (3). Remove the cap (2).

Screw in the 7 screws (1). Pretighten the screws to a tightening torque of 17 Nm (12 lbf·ft). Then tighten the screws to a tightening torque of 35 ÷ 45 Nm (26 ÷ 33 lbf·ft) in the sequence shown in the figure.

Check for proper timing by turning the spool clockwise and feeling pressure in the “R” port.

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NOTES:


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580T 580ST 590ST 695ST

SECTION 50 - CAB HEATING AND AIR CONDITIONING TECHNICAL SPECIFICATIONS....................................................................................................................... 3 GENERAL.................................................................................................................................................... 3 CAB HEATING.................................................................................................................................................. 5 CONTROLS ................................................................................................................................................. 5 OPERATION................................................................................................................................................ 6 AIR FLOW DIFFUSERS .............................................................................................................................. 7 OVERHAUL ................................................................................................................................................. 9 TROUBLESHOOTING............................................................................................................................... 11 AIR CONDITIONING ...................................................................................................................................... 12 PRINCIPLES OF AIR CONDITIONING ..................................................................................................... 12 CONTROLS ............................................................................................................................................... 17 OPERATION.............................................................................................................................................. 18 TROUBLESHOOTING AND TESTING...................................................................................................... 25 FLUSHING THE SYSTEM......................................................................................................................... 43 DRAINING THE SYSTEM ......................................................................................................................... 45 CHARGING THE SYSTEM........................................................................................................................ 46 OVERHAUL ............................................................................................................................................... 47 COMPRESSOR .............................................................................................................................................. 52 TECHNICAL SPECIFICATIONS................................................................................................................ 52 REMOVAL AND INSTALLATION .............................................................................................................. 53 DISASSEMBLY AND ASSEMBLY............................................................................................................. 56 TROUBLESHOOTING............................................................................................................................... 65

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SECTION 50 - CAB HEATING AND AIR CONDITIONING

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TECHNICAL SPECIFICATIONS GENERAL ENGINE RADIATOR COOLANT Anti-freeze - Akcela Premium .................................................................................................12 litres (2.64 gal) Water ......................................................................................................................................12 litres (2.64 gal) System type ........................................................... Pressurized FULL FLOW by-pass with expansion chamber FAN BELT DEFLECTION Natural suction ........................................................................................................ 13 ÷ 19 mm (0.51 ÷ 0.75 in) Turbocharged.......................................................................................................... 10 ÷ 16 mm (0.39 ÷ 0.63 in) THERMOSTAT Opening starts at.......................................................................................................................... 82 °C (179 °F) Fully open at ................................................................................................................................ 95 °C (203 °F) Radiator cap.............................................................................................................................. 0.90 bar (13 psi) MOUNTING SCREW TORQUE Coolant/hot water hose connections ...........................................................................................5 Nm (3.7 lbf·ft) Air hose connections...................................................................................................................5 Nm (3.7 lbf·ft) Heater housing to floor fastening screws .................................................................................6.2 Nm (4.6 lbf·ft) COOLANT Type .................................................................................................................................................... HFC 134a Coolant quantity ............................................................................................................................ 1.2 kg (2.6 lb) COMPRESSOR OIL Type ......................................................................................................... SP20 (PAG type, viscosity index 100) Oil change amount................................................................................................................. 135 cm3 (8.24 in3) CHECK CONDITIONS Air inlet temperature.................................................................................................................. 37.8 °C (100 °F) Rated air inlet humidity ................................................................................................................................ 40% Evaporation temperature ................................................................................................................. 0 °C (32 °F) Overheating ..................................................................................................................................... 5 °C (41 °F) Inlet air speed ...............................................................................................1.0 - 2.0 - 3.0 m/s (3.3-6.6-9.9 ft/s) Condensation temperature .............................................................................. 58 °C (136 °F) (16 absolute bar) Undercooling .................................................................................................................................... 2 °C (35 °F)

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PERFORMANCE Performance calculated at 1 m/s (3.28 ft) [191.72 m3/h (6769.31 ft3)] Exchanged heat ................................................................................................. 5.48 kW

4718.28 kcal/h

Air outlet temperature......................................................................... 5.64 °C (42.15 °F) Air side load loss ............................................................................................. 2.97 daPa ....................................................................................................................(0.00431 psi)

0.30 mmH20 (0.012 inH20)

Coolant side load loss ....................................................................................... 13.1 kPa

0.13 bar (1.9 psi)

Performance calculated at 2.0 m/s (6.56 ft) [383.4 m3/h (13537.22 ft 3)] Exchanged heat ................................................................................................. 9.29 kW

7,998.69 kcal/h

Air outlet temperature....................................................................... 10.30 °C (50.54 °F) Air side load loss ............................................................................................. 9.34 daPa ..................................................................................................................... (0.0135 psi)

0.95 mmH20 (0.037 inH20)

Coolant side load loss ....................................................................................... 32.7 kPa

0.33 bar (4.8 psi)

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Performance calculated at 3.0 m/s (9.84 ft) [575.1 m /h (20305.83 ft )] Exchanged heat ............................................................................................... 12.00 kW

10332.00 kcal/h

Air outlet temperature....................................................................... 13.70 °C (56.66 °F) Air side load loss ........................................................................................... 18.30 daPa ...................................................................................................................... (0.0265psi)

1.87 mmH20 (0.074 inH20)

Coolant side load loss ..................................................................................... 51.20 kPa

0.51 bar (7.4 psi)


CAB HEATING The cab is heated by a radiator mounted below the cab seat, which is supplied hot water from the engine coolant system. A blower motor mounted behind the cab radiator is used to transfer the heat into the cab.

CONTROLS Heater blower control The three-speed blower is controlled by means of a knob (1) on the instrument console, to the right of the operator’s seat. Turn clockwise to the first position for slow speed. A further clockwise rotation selects medium and fast speeds. The blower draws outside air from beneath the cab floor and blows it into the cab through a filter. Temperature control The temperature of the air coming from the radiator is adjusted by rotating the control knob (2), which opens or closes the radiator valve, thus increasing or decreasing the water flow as required. Turn clockwise to increase the temperature of the air coming from the heater. By rotating counterclockwise, the temperature is decreased.

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OPERATION CAB AIR FILTER Before servicing the air filter situated under the operator’s seat, switch off the blower and close all windows and one door. Forcibly close the other door. The resulting back pressure will dislodge loose dirt from the underside of the filters. To remove the filter (1), release the retaining straps (2) and remove the filter element. Ensure the element, and sealing faces are not damaged on removal. IMPORTANT: in humid conditions, such as occur on most early mornings, do not switch on the blower prior to servicing the filters. Damp particles drawn into the filter may solidify and prove difficult to remove without washing. The filter element is made of specially treated paper with a sealing strip bonded to the outer face. Clean this element by blowing with compressed air from the clean side through to the dirty side. The compressed air should not exceed 2 bar (29 psi) and the air line nozzle should be at least 300 mm (11.8 in) from the element. HEATER RADIATOR The heater radiator (1) is fitted in a housing under the cab seat to guarantee a uniform distribution of warm or cold air flow. IMPORTANT: to ensure a good flow of air through the heater radiator the filter should be cleaned more frequently when operating in extremely dusty conditions.


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AIR FLOW DIFFUSERS Air flow diffusers are connected to the heating system and receive air from the blower, to direct warm or cold air onto the windshield and side windows or into the cab, as required. Each diffuser may be swivelled and adjusted to control the flow of air. To open a diffuser, press one side of the disc and turn it, as required, to direct the air flow. The diffusers are located as follows: - two on the top of the front control panels (A); - two to the rear of the seat (C); - two under the seat, one in front, the other on the rear (D); - two on the cab posts, right and left (B); - two on the ceiling, in front and back of operator’s head (E). NOTE: the diffusers (B) and (E) are mounted only when air conditioning (optional) is fitted.

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ELECTRIC HEATER VALVE The electric valve is equipped with a software that, each time the supply of the cock is delayed (therefore also at backhoe loader start), carries out the momentary positioning of the cock to “completely closed” and returns to the position set by the temperature regulation handle located on the control dashboard. This enables the software to carry out a self-control on the cock drive so as to always obtain an optimal regulation of the ball for the water flow. This is part of the cock normal operation and is not to be considered as a fault. Valve release IMPORTANT: the release of the valve has to be performed if this valve remains idle for long periods. Carry out this operation observing the following procedure: - disconnect the electric connectors (1); - loosen the screws (2) and extract the electric valve (3) from the evaporator; - loosen and remove the screws (4);

- separate the driving unit (5) from the cock (6); - by means of a wrench, turn the pin (A) of the cock to unlock it.

WARNING Once this operation is complete, reset pin (A) in the correct start position.

Reinstall the heater valve, repeating the previously carried out operations in reverse order.


OVERHAUL IMPORTANT: when overhauling the heating system remember that, with the engine running or shortly after it is turned off, the system will be at engine temperature and therefore the water will be hot and under pressure. To carry out the different checks and operations, it is necessary to drain the system. To drain the cooling system, disconnect either hose at the union tee (1) found behind the engine oil filter, mounted to the left-hand side of the engine.

RADIATOR CHECK With the system drained, remove the heater radiator hose connections, the attaching screws and remove the radiator from the vehicle. Inspect the radiator (2). Check that the water flows freely through the heater line (otherwise, clear any obstruction). Fins must be free from debris and not damaged: clean and/or repair. Clean the heater radiator using compressed air not exceeding 7 bar (102 psi) taking care not to damage the radiator fins. Make sure that the radiator is not leaking under pressure. Clean the chamber with a damp, cloth and reassemble the housing filter element with the seal facing the inside of the cover.

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BLOWER MOTOR CHECKS The blower motor (3) can be removed by removing the attaching screws and disconnecting the electric connector. Check that the fan operates correctly. Otherwise, check the fuse and the continuity of the fan motor. If defective, replace the blower unit as an assembly.

HEATING VALVE To service the control valve (4), disconnect the hoses and the control tie rod and remove it. Check its operation and replace it, if worn.

CONTROL PANEL Check for the correct operation of the control knobs (5) and (6).


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TROUBLESHOOTING Items that may cause trouble are listed in the table below. Anyway, as a general rule, we recommend carrying out some preliminary checks. Ensure water flow to the heater radiator is steady and all air has been removed from the system. Hoses are unrestricted and not leaking. Check the electric connections are good and the blower motor is operational. The operating cable to the heater valve and valve is operational. TROUBLE Dust enters the cab.

Low blower motor air flow.

CAUSE

ACTION

Improper seal around filter element.

Check the seal condition.

Restricted filter.

Clean or replace the filter.

Defective filter.

Replace the filter.

Excessive air leak(s) around doors and windows.

Repair and seal air leak(s).

Blocked filter or air recirculation filter. Clean or replace the filter(s). Heater radiator core blocked.

Clean radiator core thoroughly.

Blower motor not working.

Blown fuse.

Replace fuse.

Cab does not heat up.

Engine not reaching operating Replace the temperature switch. temperature. Thermostat stuck open.

Cab does not cool down.

Temperature not stable.

Heater hose from engine to cab radiator kinked or blocked.

Ensure water flow to heater radiator is adequate and not restricted.

Heater control turned on.

Turn the temperature control knob fully counterclockwise for maximum cooling.

Heater control valve stuck in open position.

Free up valve or change as required.

Low engine coolant level.

Top up coolant recovery tank.

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AIR CONDITIONING PRINCIPLES OF AIR CONDITIONING The function of the air conditioning system is to improve the operator’s comfort by cooling down the air temperature inside the cab and reducing the humidity level. In order to achieve this heat transfer the following principals of heat generation and transfer are applied within the air conditioning system. When two bodies with a different temperature come together, heat is transferred from one to the other. On air conditioning systems, an evaporator is used to maintain the low temperature of the coolant, which absorbs the heat from the air within the cab.

When a gas is pressurized the temperature of the gas will rise. In air conditioning systems the increase in pressure is achieved using a compressor.

When a gas is cooled it will condense into a liquid. In the air conditioning system a condenser is used to cool the gas and the resulting liquid is stored in a receiver dryer.


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, coolant is atomized using an expansion valve.

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OPERATING DIAGRAM

1. Expansion valve-atomizes liquid coolant before passing to evaporator

3. Compressor-compresses and raises temperature of coolant gas

2. Evaporator-absorbs heat from air in cab

4. Condenser and receiver dryer-converts coolant from gas to a liquid


LOW PRESSURE SIDE

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HIGH PRESSURE SIDE

EXPANSION VALVE LOW TEMPERATURE HIGH PRESSURE LIQUID FILTERED AND MOISTURE REMOVED

LIQUID ATOMIZED AT A LOWER TEMPERATURE

RECEIVER DRYER

LOWER TEMPERATURE HIGH PRESSURE LIQUID

EVAPORATOR

CONDENSER

WARM LOW PRESSURE VAPOUR

HIGH TEMPERATURE HIGH PRESSURE VAPOUR

COMPRESSOR HEAT FROM INSIDE CAB MOVES TO COOLANT

HEAT MOVES TO OUTSIDE AIR FROM COOLANT

Air conditioning flow diagram

It can now be seen that the principal components of an air conditioning system are: - Coolant - Compressor - Condenser - Receiver dryer - Expansion valve - Evaporator

Coolant is drawn into the compressor as a cool, low pressure vapour which is compressed and then pumped out as a hot, high pressure vapour to the condenser. As the hot, high pressure vapour passes through the condenser core it gives off heat to the cooler outside air, being drawn past the fins by the engine cooling fan.

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By giving off heat to the outside air, the vapour is condensed to a liquid which moves under high pressure to the receiver dryer where it is stored until released to the evaporator by the temperature sensing expansion valve. As liquid coolant passes through the metered orifice in the expansion valve the coolant changes from a high pressure liquid to a low pressure atomized liquid with a lower temperature. This low pressure, low temperature, atomized liquid enters the evaporator coils and absorbs heat from the cab warm air blown across the coils and fins by the cab blower motor. The coolant now changes from a cold low pressure atomized liquid to a warm low pressure vapour and leaves the evaporator outlet, moving to the suction (low pressure) side of the compressor to repeat the cycle. As this heat loss is taking place, moisture (humidity) in the cab air will condense on the outside of the evaporator and drain off as water through the drain hoses attached to the evaporator drain pan, thereby reducing the humidity level of the cab.


CONTROLS CONTROLS (580T) The air conditioning control can be adjusted to obtain the desired temperature in the cab. To activate air conditioning, turn the selector (2). Upon activation, the lamp (3) turns on. The selector (1) allows choosing the ideal temperature according to your requirements. Positioning selector (1) to “0” and turning selector (2) you will obtain more or less cold according to the selector (2) position. By positioning selector (1) to any other position different from “0”, you will obtain instead a mixture of warm and cold air and the desired climate inside the cab. NOTE: the air conditioning can be operated only if the ventilation selector (4) is not set to the stop position. Turn the selector (4) for air capacity according to your requirements.

CONTROLS (580ST - 590ST - 695ST) The air conditioning control can be adjusted to obtain the desired temperature in the cab. To activate air conditioning, turn the selector (2). Upon activation, the lamp (4) on the side instrument cluster turns on. The selector (1) allows choosing the ideal temperature according to your requirements. Positioning selector (1) to “0” and turning selector (2) you will obtain more or less cold according to the selector (2) position. By positioning selector (1) to any other position different from “0”, you will obtain instead a mixture of warm and cold air and the desired climate inside the cab. NOTE: the air conditioning can be operated only if the ventilation selector (3) is not set to the stop position. Turn the selector (3) for air capacity according to your requirements.

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OPERATION COOLANT To achieve the absorption and the release of heat which is, in essence, the function of an air conditioning system, requires the use of a suitable “coolant” a liquid that has a relatively low temperature boiling point, plus certain desirable safety and stability features. The coolant used in the air conditioning system is coolant HFC 134a. NOTE: to help protect the environment legislation has been introduced in most territories banning the release into the atmosphere of coolants, including HFC 134a. All service procedures contained in this manual can be carried out without the need to release coolant into the atmosphere. In order to prevent the incorrect type of coolant being charged to the system the service valves fitted to the Backhoe Loader and necessary to connect up coolant recovery, evacuation and recycling/ re-charging equipment will be of two different sizes as recognized and specified by the air conditioning industry.

WARNING Coolant HFC 134a is not compatible with coolant R-12. Do not try to replace coolant HFC 134a with coolant R-12 or to test the system using instruments or tools previously used with R12, as the system could get damaged. HFC 134a coolant is stable at all operating temperatures and able to absorb great quantities of heat. The boiling point of HFC 134a is -22 °C (-7.6 °F) at atmospheric pressure. If the pressure is increased, HFC 134a will readily vaporize to absorb heat at temperatures between -11.7 °C (10.94 °F) at 1.9 bar (28 psi) and 0 °C (32 °F) at 2.9 bar (42 psi) in the evaporator. At higher pressures, HFC 134a will condense and give off heat at temperatures between 48 °C (118.4 °F) at 12.4 bar (180 psi) and 58 °C (136.4 °F) at 15.85 bar (230 psi) in the condenser.

WARNING HFC 134a can be dangerous if improperly handled. Therefore it is important the following warning and directions are adhered to. Never expose any part of the air-conditioner system to flame or excessive heat because of risk of fire or explosion, and the production of phosgene gas. Never disconnect or disassemble any part of the airconditioning system as escaping coolant can cause frostbite.

WARNING If coolant should contact the skin use the same treatment as for frostbite. Warm the area with your hand or lukewarm water 32 °C (89.6 °F), cover the area loosely with a bandage to protect affected area against infection and consult a doctor immediately. If coolant should contact the eyes wash immediately in cold clean water for at least 5 minutes and consult a doctor immediately.


COMPRESSOR The compressor is mounted on the left-hand side of the engine and is belt driven by the crankshaft pulley. The compressor separates the low and high pressure sides of the system and has two functions: - raising the coolant temperature by compressing to a higher degree of temperature than the ambient (outside air) temperature; - circulating the required volume of coolant through the system. The compressor is a 7-cylinder wobble plate unit, housed in a die-cast aluminium housing. The drive to the wobble plate comes from the pulley, through the clutch to the main driveshaft. Attached to the driveshaft, there is a cam rotor which oscillates the wobble plate. The wobble plate is prevented from rotating by a static gear engaging with teeth formed in the face of the plate. The seven pistons are connected to the wobble plate by rods located in ball sockets. Coolant is drawn in on the downward stroke of a piston through the reed valves located either end of the cylinder assembly. Coolant enters the cylinder assembly through a gallery in the outer circumference of the cylinder assembly. During the upward stroke, the piston compresses the coolant and expels it through another reed valve into an inner gallery in the cylinder and, from here, out into the coolant system. The compressor is lubricated with a Polyalklene Glycol (PAG) oil Type SP20. This oil can be mixed with coolant and is carried around in the coolant system itself. During the operation of the air conditioning system, the compressor is activated by a clutch which engages or disengages it as required.

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TEMPERATURE SENSOR The air conditioner temperature adjusting sensor is mounted on the blower motor. It is a device which turns the compressor clutch on and off to maintain a constant average evaporator temperature and senses the evaporator temperature using a thermistor (1). The sensor compares the voltage of the thermistor, which depends on the temperature of the evaporator, with the voltage across the potentiometer of the “in-cab” temperature control switch. The switch upon comparing the two voltages determines whether the compressor clutch should be switched “on” or “off” in order to maintain the desired in cab temperature control. LOW-PRESSURE CUT-OUT SENSOR The low-pressure sensor (1) is on the upper part of the filter, situated in front of the radiator. The purpose of the sensor is to shut off the compressor in case of low pressure in the cooling system. Low coolant pressure may occur due to a faulty expansion valve, icing up of the expansion valve orifice or coolant loss. Low coolant pressure may result in damage to the compressor pump. The low-pressure sensor is set by the Manufacturer.


CONDENSER The condenser (1), located at the front of the machine in front of the engine radiator consists of a number of turns of continuous coil mounted in a series of thin cooling fins to provide a maximum of heat transfer in a minimum amount of space. The condenser receives the hot, high pressure coolant vapour from the compressor. The hot vapour passes through the condenser coils and outside air is drawn through the condenser by the engine cooling fan. Heat moves from the hot coolant vapour into the cooler outside air flowing across the condenser coils and fins. When the coolant vapour reaches the pressure and temperature that will induce a change of state, a large quantity of heat is transferred to the outside air and the coolant changes to a high pressure warm liquid. The warm liquid coolant continues onto the receiver/drier where it is filtered and desiccated, to remove any moisture, before passing through an outlet line to the thermostatic expansion valve.

RECEIVER DRYER The receiver/dryer (1) stores the liquid coolant to make sure that a steady flow to the expansion valve is maintained also under extremely different operating conditions. The drier contains a desiccant (molecular sieve) which absorbs any moisture within the system, and a filter which prevents the entry of foreign particles. NOTE: any moisture in the air conditioning system is extremely harmful. Moisture not absorbed by the dehydrator will circulate with the coolant and droplets may collect and freeze in the thermostatic expansion valve orifice. This action will block the coolant flow and stop the cooling action. Moisture will also react with coolant HFC 134a and the lubricant to form a corrosive acid. The desiccant can only absorb a limited amount of moisture before reaching saturation point. Because of this, after any system component replacement or repairs requiring entry into the system, the receiver/ dryer should be replaced.

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EXPANSION VALVE The expansion valve (1) is located underneath the evaporator in the pressure line coming from the receiver/dryer and performs the following functions: - metering action (a metering orifice changes the liquid coolant from a high-pressure low-temperature liquid to a lowpressure, lower-temperature atomized liquid); - modulating action (a thermostatically controlled valve within the expansion valve body controls the volume of liquid coolant passing through the orifice and makes sure that the coolant is fully vaporized within the evaporator; the liquid coolant could damage the compressor reed valves or freeze the pistons); - control action (the valve responds to changes in the cooling requirements; when an increased cooling is required, the valve opens to increase the coolant flow, and when less cooling is required, the valve closes and decreases the coolant flow).

Operation All of the needed temperature sensing and pressure sensing functions are consolidated into this basic unit and no external tubes are required for these purposes. The coolant from the condenser and receiver dryer enters the thermostatic expansion valve as a high pressure warm liquid. Upon passing through the ball and spring controlled metering orifice, the pressure and temperature of the coolant is reduced and the coolant leaves the thermostatic expansion valve as a low pressure, lower temperature atomized liquid. The atomized liquid now passes through the evaporator where it absorbs heat before returning via the expansion valve to the compressor as a warm low pressure vapour. There are two coolant passages in the valve. One passage is in the coolant line from the condenser to the evaporator and contains the ball and spring type orifice valve.


The other passage is in the coolant line from the evaporator to the compressor and contains the valve’s temperature sensing element. Liquid coolant flow from the condenser and receiver dryer is controlled by a push-rod forcing the orifice valve ball off its seat and the spring exerting pressure on the ball to keep it on its seat. During stabilized (vehicle shutdown) conditions, the pressure on the bottom of the expansion valve diaphragm rises above the pressure on the top of the diaphragm allowing the valve spring to close the orifice. When the system is started, the pressure on the bottom of the diaphragm lowers rapidly, allowing the orifice to open and metre atomized liquid coolant to the evaporator where it begins to vaporize. Suction from the compressor draws the vaporized coolant out of the evaporator and back through a gallery in the top of the valve which asses the temperature sensor. The temperature sensor reacts to variations in coolant gas pressure returning from the evaporator. When heat from the passenger compartment is absorbed by the coolant the pressure of the gas increases causing a differential pressure above and below the temperature sensor diaphragm. The diaphragm reacts to this pressure differential and a push rod forces the ball in the expansion valve orifice further off its seat. This reaction allows an increase in the atomized coolant to flow through the valve, to the evaporator, so that more heat can be absorbed by the air conditioning system. Similarly when the temperature of the gas returning from the evaporator decreases the pressure of the gas decreases. This causes the diaphragm to react accordingly and allow the ball in the orifice to move closer towards its seat thus reducing the flow of coolant through the valve to the evaporator.

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EVAPORATOR The evaporator is located beneath the cab seat and consists of a number of turns of continuous coils mounted in a series of thin cooling fins to provide a maximum of heat transfer in a minimum amount of space. Low temperature coolant in the evaporator absorbs heat from the hotter air in the operator’s compartment, thereby cooling the air.

An intake grille is located on the left side of the seat base. A portion of the air flow will recirculate through the evaporator.

AIR FILTER The blower fan draws warm air from outside the cab through the intake filter (2) below the cab floor and a ready cooled dehumidified air through the recirculation grille (1). The air passes over the evaporator then into the cab through the six louvered diffusers. Two diffusers are located on the front instrument panel to direct air onto the windshield. Two are located at the base of the rear posts to direct air onto the rear window. Two additional vents are located at the front and rear of the seat base to direct air at the operator’s feet.


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TROUBLESHOOTING AND TESTING Overhaul of the air conditioning system should only be undertaken by a certified specialist refrigeration engineer using a comprehensive air conditioning test kit, including a gas leak detector, suitable for HFC 134a coolant gas.

WARNING Before dismantling an air conditioning system for repair the gas within the system must be discharged and recovered using a certified recovery unit designed for the type of coolant gas used in the system. NEVER release coolant gas into the atmosphere. ALWAYS wear safety goggles and gloves when servicing any part of the air conditioning system. To prevent the entry of any foreign material, it is necessary to observe some precautions. Ensure all tools, gauges, hoses and replacement parts are kept clean and dry and are suitable for the type of coolant gas used in the system.

PRELIMINARY CHECKS Always conduct the preliminary fault finding checks before performance testing the system. Run the engine at 1000-1200 rpm for 10 minutes with the air conditioner set to maximum cooling and the blower at high speed. Check that the heater temperature control is switched OFF. Check that the blower fan is operating at all speeds. Check that the compressor clutch engages when the temperature control switch is turned from OFF to ON position. A clicking sound indicates the clutch is engaging. If the clutch fails to operate it may indicate an electric problem in the high low pressure cut out switches or malfunction of the electric drive clutch on the compressor. Check the engine cooling fan is drawing cool air through the condenser.

Clean all hoses and fittings before disconnecting.

Check the compressor drive belt tension.

Cap or plug all openings when disconnected.

Check the condenser core and grid is clean and free of obstruction.

When adding lubricating oil to the system always uncap and re-cap the oil container immediately before and after use. Always ensure the oil remains free of moisture.

Check the cab air filter is clean and free of obstruction. Check the evaporator fins are not plugged or excessively dirty.

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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. Low pressure (suction) side service valve

4. Test hose to high side service connector

9. High pressure (discharge) side service valve

5. Centre hose (not used)

Performance testing the air conditioning system The manifold gauge set is the most important tool used in testing and servicing the air conditioning system. NOTE: for Dealers who posses the latest design level of coolant recovery, recycling and recharging station, these gauges are an integral part of the machine. The following instructions for performance testing the air conditioning system is based on the use of the gauge set shown. The principal of operation is however similar when testing the system using a recovery and recharging station with integral gauges. When using this type of equipment always consult the manufacturers operating instructions.

Operating precautions IMPORTANT: always ensure the shut-off valves are closed (turn clockwise until seated) during all test operations. In the closed position, coolant circulates around the valve stems to the gauges. Therefore, when the manifold gauge set is connected into a system, pressure is registered on both gauges. - NEVER open the HIGH SIDE shut off valve when the system is operating. - ALWAYS open the LOW SIDE shut off valve when adding coolant.


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Attaching the gauge set to the backhoe loader

WARNING To avoid personal injury, stop the backhoe loader engine during connection of the manifold gauge set. Check that the gauge set shut off valves are closed (turned fully clockwise). Connect the high side gauge hose (normally red) to the high pressure (discharge) side service valve and the low side gauge hose (normally blue) to the low pressure (suction) side service valve on the backhoe loader. Ensure the hose connections are fully tightened. IMPORTANT: prior to connection of the manifold gauge set, identify the suction (low pressure) and discharge (high pressure) service gauge ports. The high pressure service valve is always in the line from the compressor to the condenser. The high and low pressure service valves on the backhoe loader are spring-loaded valves and will be automatically opened when the test hose is connected. NOTE: the test hose must incorporate a valve depressor to actuate this type of valve. The service valves have a protective cap. This cap must be removed for test gauge connections and replaced when service operations are completed. Test procedure

Re-check that both the high and low side shut off valves on the manifold gauge set are fully closed. Run the engine at 1000 ÷ 1200 rpm. Turn the heater temperature control OFF. Operate the system at maximum cooling, with the blower fan at high speed for 10 minutes to stabilize all components. Check the manifold low pressure gauge reading is within the specified range of approximately 0.28 ÷ 2.48 bar (4.06 ÷ 35.97 psi). Check the manifold high pressure gauge reading and compare the reading to the pressure indicated on the pressure temperature chart below. Measure and compare the temperature of conditioned air entering the cab through the louvered air diffusers with the ambient air at the air intake filters on the outside of the cab. If the system is operating correctly, the conditioned air entering the cab should be 6 - 9 °C (42.8 - 48.2 °F) cooler than the ambient temperature of the outside air. If it is confirmed that the system is not operating correctly refer to the fault diagnostic charts and performance test gauge reading examples on the following pages for possible corrective action.

WARNING

After the manifold gauge set has been connected and before pressure tests can be made, the system must be stabilized as follows: Apply the parking brake, check the gearshift levers are in neutral and close the cab windows and doors.

A significant amount of coolant vapour may have condensed to a liquid at the service fitting at the high side of the compressor. Use a cloth or other protective material when disconnecting the manifold hose from this fitting to prevent personal injury to hands and face.

APPROXIMATE HIGH PRESSURE GAUGE READINGS Ambient air temperature

High pressure gauge reading

°C (°F)

bar (psi)

27 (80.6)

10.0 / 11.6 (145 / 168)

29 (84.2)

11.2 / 12.7 (162 / 184)

32 (89.6)

12.3 / 13.8 (178 / 200)

35 (95)

13.3 / 15.2 (193 / 220)

38 (100.4)

14.5 / 16.7 (210 / 242)

41 (105.8)

16.0 / 18.3 (232 / 265)

43 (109.4)

17.3 / 20.0 (251 / 290)

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PERFORMANCE TEST DIAGNOSIS Pressure gauge values:

Low pressure - Low High Pressure - Low

TROUBLE Evaporator air not cold.

CAUSE Low coolant charge.

ACTION Perform leak tests and repair. Drain the system. Charge system, re-test system.

Evaporator air warm.

Very low coolant charge.

Perform leak tests and repair. Drain the system. Charge system, re-test system.

Evaporator air cool, but not Expansion valve not permitting sufficiently cold. sufficient flow.

Check expansion valve as follows:

Low pressure switch cutting out.

Low pressure gauge should lower slowly.

Expansion valve to evaporator tube shows considerable condensation or frost. Too cold to touch.

Stuck valve.

Set for maximum cooling.

If expansion valve is defective: Discharge the system. Replace the expansion valve. Drain the system. Charge the system. Re-test.


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PERFORMANCE TEST DIAGNOSIS CHART Pressure gauge values:

TROUBLE Evaporator air warm.

Low pressure - High High Pressure - High CAUSE Improper operation of condenser.

Liquid line hot (condenser outlet to expansion valve tube). High pressure switch cutting out.

ACTION Inspect for dirty condenser restricting air flow and cooling. Check operation of condenser cooling fans. Repair or replace as needed.

Overcharged with coolant.

Check for overcharge as follows:

Air in the system.

Stop the engine. Recover and recycle the charge using correct recovery equipment. Recharge the system with the correct quantity of coolant, replacing any lost lubricant. Recheck performance of air conditioning system.

Evaporator air not cold.

Expansion valve allowing too much Check expansion valve as follows: coolant to flow through the evaporator. Set for maximum cooling. Low pressure gauge should lower slowly. If expansion valve is defective: Discharge the system. Replace the expansion valve. Drain the system. Charge the system. Re-test.


Low pressure - Low High Pressure - High

TROUBLE

CAUSE

Insufficient cooling.

Restriction in liquid line.

ACTION Discharge the system. Replace receiver/drier. Inspect all lines and tubing from compressor outlet to expansion valve. Replace if needed. Drain the system. Charge the system. Re-test.

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Low pressure - High High Pressure - Low

TROUBLE

CAUSE

Evaporator air not cold.

Internal leak in compressor (reed valves, gasket, worn or scored piston rings or cylinder).

ACTION Discharge the system. Replace the compressor. Drain the system. Charge the system. Re-test.


Low pressure - Normal High Pressure - Normal

TROUBLE

CAUSE

Insufficient cooling. Low pressure reading does not fluctuate with changes in temperature control switch (pressure should lower until compressor cycles).

System low on charge. Air or moisture in system.

ACTION Perform leak test. Discharge the system. Repair leaks. Replace receiver/drier. Check oil level. Drain the system.

Evaporator air not cold

Charge the system. Re-test.


TROUBLE Compressor cycles ON and OFF too frequently.

Low pressure - High High Pressure - Normal CAUSE Defective temperature control (thermostatic) switch.

ACTION Stop engine and shut off air conditioning. Replace temperature control switch. Re-test system and check compressor cycling.


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EXAMPLES OF MANIFOLD GAUGE READINGS AND INTERPRETATIONS The following examples show typical low and high pressure gauge readings obtained when performance testing the air conditioning system with an ambient temperature of 35 °C (95 °F). The recommended corrective action is based on a similar fault as identified in the performance test diagnosis charts. Performance Test Example 1

1. High side low 2. High side hand valve closed 3. High side hose connected to high side service connector

5. Low side hose connected to low side service connector 6. Low side hand valve closed 7. Low side low

4. Not used

Problem Little or no cooling. Cause Coolant slightly low. Conditions* Too low pressure on low-pressure side. The gauge should read 1 ÷ 2 bar (14.5 ÷ 29 psi).

Repair leaks. (Discharge and recover the coolant from the system; replace lines or components). Check compressor oil to ensure no loss. Drain the system. Charge the system. Performance test the system. Diagnostic System coolant is low. May be caused by a small leak.

Too low pressure on high-pressure side. The gauge should read 13.3 ÷ 14.8 bar ((193 ÷ 215 psi)). Evaporator air not cold.

Corrective procedures Leak test the system.

NOTE: * test procedure based upon ambient temperature of 35 °C (95 °F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

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Performance Test Example 2


5. Low side hose connected to low side service connector 6. Low side hand valve closed 7. Low side normal

4. Not used

Problem

Corrective procedures


Leak test the system.

Cause

Discharge and recover the coolant from the system.

Coolant excessively low. Conditions* Low side pressure very low. The gauge should read 1 ÷ 2 bar (14.5 ÷ 29 psi). Too low pressure on high-pressure side.

Repair leaks. Check compressor oil to ensure no loss. Drain the system. Charge the system.

The gauge should read 13.3 ÷ 14.8 bar ((193 ÷ 215 psi)).

Performance test the system.

Evaporator air warm.

System coolant is extremely low. A serious leak is indicated.

Low pressure switch cutting out.

Diagnostic



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1. High side normal 2. High side hand valve closed 3. High side hose connected to high side service connector


4. Not used

Problem



Leak test the system. Give special attention to the compressor seal area.

Cause Air in the system. Conditions* Low side pressure reading does not change when compressor cycles ON and OFF. High side pressure slightly high or slightly low. The gauge should read 13.3 ÷ 14.8 bar ((193 ÷ 215 psi)). Evaporator air not cold.

Discharge and recover the coolant from the system. Repair leaks. Replace receiver/drier. Check compressor oil to ensure no loss. Drain the system. Charge the system. Performance test the system. Diagnostic Air or moisture in system. System not fully charged. NOTE: * test procedure based upon ambient temperature of 35 °C (95 °F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

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5. Low side hose connected to low side service connector 6. Low side hand valve closed 7. Low side high

4. Not used

Problem



Replace the compressor.

Cause

Diagnostic

Compressor malfunction.

Internal leak in compressor caused by worn or scored pistons, rings, or cylinders.

Conditions* Low side pressure too high. The gauge should read 1 ÷ 2 bar (14.5 ÷ 29 psi). Too low pressure on high-pressure side. The gauge should read 13.3 ÷ 14.8 bar ((193 ÷ 215 psi)). Evaporator air not cold.



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1. High side high 2. High side hand valve closed 3. High side hose connected to high side service connector


4. Not used

Problem Little or no cooling. Engine overheats in some cases. Cause Condenser not functioning properly. Conditions* Low side pressure too high. The gauge should read 1 ÷ 2 bar (14.5 ÷ 29 psi). High side pressure too high. The gauge should read 13.3 ÷ 14.8 bar (193 ÷ 215 psi). Liquid line hot. Evaporator air warm. High pressure switch cutting out. Corrective procedures Check belt. Loose or worn drive belts could cause excessive pressures in the compressor head. Look for clogged passages between the condenser fins and coil, or other obstructions that could reduce condenser airflow. If engine is overheating replace engine thermostat and radiator pressure cap.

At this point, operate the system and check its performance. If still unsatisfactory, proceed as follows: - discharge and recover the coolant from the system; - remove the condenser, clean and flush it to ensure a free flow of coolant. Otherwise, if the condenser appears to be particularly dirty or obstructed, replace it; - replace the receiver/drier; - drain the system and recharge it with the correct quantity of coolant; - carry out the performance test of the system. Diagnostic Lack of cooling caused by pressure that is too high on the high side, resulting from improper operation of condenser. (Coolant charge may be normal or excessive). NOTE: * test procedure based upon ambient temperature of 35 °C (95 °F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

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5. Low side hose connected to low side service connector 6. Low side hand valve closed 7. Low side normal

4. Not used

Problem


Little or no cooling.

Discharge and recover the coolant from the system.

Cause Large amount of air in system. Conditions* Low side pressure too high. The gauge should read 1 ÷ 2 bar (14.5 ÷ 29 psi). Too low pressure on high-pressure side. The gauge should read 13.3 ÷ 14.8 bar (193 ÷ 215 psi). Evaporator air not cold.

Replace receiver/drier. Drain the system. Charge the system. Performance test the system. Diagnostic Air in the system. Air and humidity contained in it contaminate the system: therefore, it will operate incorrectly. NOTE: * test procedure based upon ambient temperature of 35 °C (95 °F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.


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1. High side high 2. High side hand valve closed 3. High side hose connected to high side service connector


4. Not used

Problem Little or no cooling.

If the test indicates that the expansion valve is defective, proceed as follows:

Cause

- discharge and recover the coolant from the system;

Improper operation of thermostatic expansion valve (stuck open).

- replace the expansion valve;

Conditions* Low side pressure too high. The gauge should read 1 ÷ 2 bar (14.5 ÷ 29 psi). High side pressure too high. The gauge should read 13.3 ÷ 14.8 bar (193 ÷ 215 psi). Evaporator air warm. Evaporator and suction hose (to compressor) surfaces show considerable moisture. Corrective procedures Check for sticking expansion valve as follows: - operate the system at maximum cooling; - check the low-pressure side gauge. The pressure should lower slowly.

- drain the system; - charge the system; - carry out the performance test of the system. Diagnostic Thermostatic expansion valve is allowing too much coolant to flow through the evaporator coils. Valve may be stuck open. NOTE: * test procedure based upon ambient temperature of 35 °C (95 °F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

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4. Not used

Problem

- operate the system at maximum cooling;


- check the low-pressure side gauge. The pressure should lower slowly.

Cause Improper operation of thermostatic expansion valve (stuck open). Conditions*

If the previous procedure indicates that the expansion valve is defective, proceed as follows: - discharge the system; - replace the expansion valve;

Low side pressure too low (zero or vacuum). The gauge should read 1 ÷ 2 bar (14.5 ÷ 29 psi).

- drain the system;

High side low. The gauge should read 13.3 ÷ 14.8 bar ((193 ÷ 215 psi)).

- carry out the performance test of the system.

Evaporator air cool, but not sufficiently cold. Evaporator inlet pipe surface shows considerable moisture or frost. Low pressure switch cutting out. Corrective procedures Place finger on expansion valve to evaporator tube. If too cold to touch, proceed as follows:

- charge the system; Diagnostic Expansion valve is not permitting a sufficient flow of coolant. May be caused by valve stuck in restricted or closed position. NOTE: * test procedure based upon ambient temperature of 35 °C (95 °F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.


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4. Not used

Problem Little or no cooling. Cause Restriction in high side of system. Conditions* Too low pressure on low-pressure side. The gauge should read 1 ÷ 2 bar (14.5 ÷ 29 psi).

- check the low-pressure side gauge. The pressure should lower slowly. If the test indicates that the expansion valve is defective, proceed as follows: - discharge and recover the coolant from the system; - replace the expansion valve;

Too low pressure on high-pressure side. The gauge should read 13.3 ÷ 14.8 bar ((193 ÷ 215 psi)).

- drain the system;

NOTE: a normal or high reading of the high side pressure gauge under these conditions indicates the system is overcharged or the condenser or receiver/dryer is too small.

- carry out the performance test of the system.

Evaporator only slightly cool. Liquid line and receiver/dryer are cool to touch and show frost or considerable moisture. Corrective procedures Check for sticking expansion valve as follows: - operate the system at maximum cooling;

- charge the system; Diagnostic Thermostatic expansion valve is allowing too much coolant to flow through the evaporator coils. Valve may be stuck open. NOTE: * test procedure based upon ambient temperature of 35 °C (95 °F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.

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5. Low side hose connected to low side service connector 6. Low side hand valve closed

4. Not used

7. Low side gauge Compressor cycles on at 2.3 bar (33.36 psi) Compressor cycles off at 1.9 bar (27.56 psi)

Problem


Compressor cycles (cuts in and out) too rapidly.

Stop engine and shut off air conditioning.

Cause

Replace thermostatic switch with switch of same type.

Thermostatic switch defective. Conditions* Low-pressure side readings are too high during both ON and OFF compressor cycles and between cycles. Readings should be: 0.8 ÷ 1.0 bar (11.60 ÷ 14.50 psi) - OFF cycle 2.5 ÷ 2.7 bar (36.26 ÷ 39.16 psi) - ON cycle 1.7 ÷ 1.9 bar (24.65 ÷ 27.56 psi) - between cycles The pressure on the high-pressure side is normal. The gauge should read 13.3 ÷ 14.8 bar (193 ÷ 215 psi).

Make sure the switch’s temperature sensor is installed in the same position and depth (in evaporator core) as previous. Performance test the system. Diagnostic Defective thermostatic switch. NOTE: * test procedure based upon ambient temperature of 35 °C (95 °F). For proper high side gauge reading for other ambient temperatures, refer to the pressure temperature chart.


LEAK TESTING, DISCHARGING AND CHARGING THE AIR CONDITIONING SYSTEM Leak testing To perform a leak test if coolant leakage is suspected, use a leak detector following the manufacturer’s instructions. Leak detectors use light or sound dependent upon the type used to alert the operator of a leak. If the leak detector’s sensitivity is adjustable, be sure you calibrate the detector according to the manufacturer’s instructions before use. When using a leak detector, keep in mind that a very slight amount of leakage in the compressor pulley area is normal and does not necessarily indicate a repair is required. When a leak is located, follow these steps. - Discharge the system using a certified coolant recovery system. - Repair the leak. - Drain the system. - Partially charge the system with 400 g (0.88 lb) of coolant. - Check system for leaks. - Fully charge the system. Always check the system for leaks as a final test after evacuating and before recharging. Refer to “Evacuating the system”. Discharging the system Legislation has been introduced banning the release of coolant into the atmosphere. Whenever overhauling the air conditioning system or performing other tasks which require the air conditioning system to be dismantled it is necessary to discharge the coolant gas before commencing repair. Before you can dismantle an air conditioning system for repairs, you must discharge and recover the coolant using a certified recovery unit in accordance with the manufacturer’s instructions. Shown is a combined coolant recovery, evacuation and recycling/charging station. This equipment removes HFC 134a coolant from the air conditioning system, recycles and recharges all in one hook up. The unit is designed to be used with the manifold gauge set built into the control panel.

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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 manifold gauges are not an integral part of the machine. When this type of equipment is used a separate manifold gauge set must be used.

ting and the blue (low side) hose to the low side (suction) fitting.

The following is a summary of the steps for discharging the system using a recovery/recycling unit.

WARNING Never discharge coolant gas into the atmosphere. Always wear safety goggles and gloves when working with coolant. Only use authorized coolant tanks. IMPORTANT: always follow the manufactures instructions when operating recovery equipment. Run the vehicle’s air conditioning system for a few minutes. Set up the recovery unit following manufacturer’s instructions. Ensure that the units red (high side) hose is connected to the high side (discharge) fit-

NOTE: if a unit requiring the manifold gauge set is being used, the low and high sides of the manifold set are connected to the low and high sides of the backhoe loader air conditioning system. The hose from the recovery unit is then connected to the manifold centre port. To recover coolant, open both high and low side valves on the control panel or the valves on the manifold gauge set if being used. Open the valves labelled “gas” and “liquid” on the recovery unit coolant tank. Plug in the unit’s power cord. Operate the recovery system in accordance with the manufacturers instructions. The compressor will shut off automatically when the recovery is complete.


FLUSHING THE SYSTEM

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. Low side gauge

4. Centre service hose

Air conditioning systems may occasionally become contaminated with solid particles. This contamination may be the result of allowing dirt to enter the system while it was open, from aluminium corrosion or sludge, or from disintegrated compressor reed plates. Contamination of this nature can result in plugged evaporators, condensers and expansion valves. Flush System with dry nitrogen. Each individual component must be flushed after disconnecting every hose fitting. The compressor and expansion valve can not be flushed, therefore, the compressor should be disassembled and cleaned or replaced and the expansion valve should be replaced. When flushing the system always replace the receiver/drier.

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NOTE: for flushing the air conditioning system, never use any solvent other than the special flushing solvent specifically produced for air conditioning systems. Always follow the manufacturer’s recommendations and directions for using the flushing equipment and solvent. Re-assemble and evacuate the system to remove air and moisture as described in “Evacuating the System”.


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DRAINING THE SYSTEM IMPORTANT: a system in which coolant has been recovered to facilitate repairs must be drained before new coolant is filled in. Air and moisture are removed by evacuating the system using a vacuum pump.

If a combined recovery/evacuation unit is to be used attach the unit to the air conditioning system in accordance with the manufacturers instructions. Be sure to read all installation and operating instructions carefully before starting the unit.

The automatic recycling, recharge and evacuation stations or evacuating and charging stations available throughout the air conditioning industry incorporate a vacuum pump within the assembly. If this type of equipment is not available a separate vacuum pump and manifold gauge set must be used.

After starting the evacuation cycle, note the low side gauge to be sure the system pulls down into a vacuum.

As the system is evacuated the boiling point of any moisture within the system is similarly lowered. As the vacuum increases the boiling reduces to below that of the ambient temperate and the moisture is subsequently boiled away. The relationship of system vacuum to the boiling temperature at which the water vapour is removed from the system is as follows: System Vacuum

System Vacuum

Temperature

In mercury

Cm (in) of mercury

°C (°F)

28.0

71.0 (28.9)

38 (100.4)

28.9

73.4 (29.0)

27 (80.6)

29.4

74.6 (29.4)

16 (60.8)

29.7

75.4 (29.7)

5 (41)

29.8

75.7 (29.8)

-7 (19.4)

29.9

75.9 (29.9)

-18 (-0.4)

NOTE: for every 305 m (1000 ft) above sea level, the vacuum gauge reading must be corrected by adding 2.54 cm (1 in) of mercury to compensate for the change in atmospheric pressure. IMPORTANT: be sure the system is completely discharged as coolant will damage the vacuum pump. If the manifold gauge set is being used connect the low and high sides of the manifold to the low and high sides of the vehicle air conditioning system as described for discharging the system. Connect the manifold centre hose to the vacuum pump suction port as per the manufacturers instructions. Fully open both the low and high side gauge shut off valves.

Time the evacuation for a minimum of 30 minutes from the point when lowest vacuum is attained. Thirty minutes later when the low side gauge attains the lowest steady vacuum, stop the evacuation process. NOTE: the vacuum pump achieves ultimate vacuum with the vented exhaust valve closed. Do not evacuate too quickly as oil may be drawn from the system. Check the system by closing the gauge shut-off valves, turning the vacuum pump off and noting the low side gauge reading. A loss of more than 5 cm (1.97 in) of vacuum in 5 minutes indicates either a leak or moisture in the system. If the gauge needle remains stationary and the vacuum is maintained for 3-5 minutes, close both the high and low side manifold hand valves, turn off and disconnect the centre hose from the pump. The system is now ready for charging. If a leak is detected, charge the system with approximately 400 g (0.88 lb) of coolant, see charging the system and locate the leak using a leak detector. Once the leak is located discharge and recover the coolant in the system, repair the leak, then repeat the evacuation procedure.

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CHARGING THE SYSTEM IMPORTANT: make sure that there are no leaks in the system and that the system has been fully drained. Observe all safety recommendations when handling coolant HFC 134a, see “Precautions when Handling coolant HFC 134a” in this Section. Ensure the charging unit is correctly connected to the backhoe loader air conditioning system in accordance with the manufacturers instructions. If a charging unit, in conjunction with the manifold gauge set is used, open the high and low side hand valves on the manifold. Charge the system with 0.75 kg (1.65 lb) of coolant as per the manufacturers instructions. If the charging rate becomes very slow close the high side valve carefully, start the backhoe loader and set engine speed to idle. Turn ON the air conditioning so that the compressor can pull the remainder of the coolant into the system.

If the coolant charge will not completely transfer to the air conditioning system, recover and recharge the system. Close the high and low side valves on the unit control panel, or on the gauge assy if being used, and test the air conditioning as described in the paragraph relevant to the performance test of the air conditioning system. NOTE: after charging a system use the following start up procedure to ensure the lubricating oil is properly dispersed around the system. - Ensure air conditioning is switched OFF. - Start the engine and bring speed down to idle. - Turn the air conditioning ON and allow system to operate for at least one minute before increasing engine speed.

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)


OVERHAUL WARNING Before disconnecting components in the air conditioning system the coolant gas must be discharged and recovered using a certified recovery system. Refer to Discharging the system. Do Not discharge the gas into the atmosphere. If an air conditioning component is to be replaced during a system overhaul it is necessary to drain any coolant oil that has collected in the component being replaced into a clean calibrated container. A volume of clean coolant oil equivalent to that removed from the replaced component must then be added to the new item before being installed onto the backhoe loader. Upon completion of the repair evacuate, recharge, leak test and performance test the system to ensure correct operation.

EXPANSION VALVE The expansion valve is not a serviceable item and must be replaced if defective. Fully discharge the air conditioning system. Remove the seat to gain access to the valve. To gain access to the expansion valve partially lift the evaporator core from its position in the cab floor. Remove the screw securing the inlet and outlet connections to the valve and pull valve from tubing. Replace the O-ring seals and lubricate with coolant oil prior to installing the valve using disassembly procedure in reverse. Evacuate, leak test and recharge the system.

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EVAPORATOR Discharge and recover coolant gas using certified recovery systems. Remove the seat and cover plate to reveal evaporator assembly (1). Remove temperature cycling control thermocouple. Disconnect tubing to expansion valve. Remove evaporator. Check the evaporator assembly fins for damage. Straighten fins if necessary. Clean the evaporator core of all foreign material to be sure it is free of obstructions. Check the evaporator assembly for indications of coolant leakage. If damage or leaks are evident, replace the evaporator core. If a new evaporator is to be installed drain the coolant oil in the evaporator into a clean calibrated container. Measure the quantity of oil obtained and add the same quantity of new coolant oil directly into the replacement evaporator core. Install evaporator using disassembly procedure in reverse. Evacuate, leak test and recharge the system. ADJUSTING SENSOR OF AIR CONDITIONER TEMPERATURE Remove the seat mounting plate. The temperature adjusting sensor (2) is mounted to the side of the blower motor assembly. Carefully pull and disconnect the switch wiring at the connector. Remove temperature control switch and replace as required.


LOW-PRESSURE CUT-OUT SENSOR With the engine OFF check continuity across the switch contacts. If the sensor (1) indicates an open circuit, replace it as described below. IMPORTANT: the sensor cannot be replaced without discharging the system. Remove the sensor by unscrewing it from the valve. Replace with new switch and connect to harness.

BLOWER MOTOR ASSEMBLY The blower motor (2) can if required be removed without discharging the system as follows: Remove the cab seat mounting plate. NOTE: take care not to damage hoses during this operation. If the cab heater hoses restrict movement of the housing drain the heater assembly and disconnect the hoses. Disconnect the motor wiring connector block. Remove the remaining motor securing screws and withdraw motor. Re-assembly follows the disassembly procedure in reverse. RECEIVER DRYER The receiver/dryer (1) cannot be overhauled and must be replaced as an assembly. The receiver/ dryer assembly should be replaced if it is suspected that moisture is in the system. The receiver dryer must also be replaced if the system has been discharged and the air conditioning joints disconnected. Discharge and recover coolant gas using certified recovery systems. Disconnect the hoses and switch and remove the dryer from the backhoe loader. Drain the coolant oil from the receiver dryer into a clean calibrated container. Measure the quantity of oil obtained and add the same quantity of new coolant oil directly into the new item. Cap and plug all fittings to prevent any dirt entering the system. Install a new receiver dryer.

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CONDENSER Loosen and remove the fixing screws (2). Remove the front grill (1).

Unscrew and remove the nut (3). Remove the horn (4). Unscrew and remove the nut (5). Remove the fuel cooler (6).

Unscrew and remove the fixing upper nut (7) and loosen the fixing lower nut. Move the dryer filter (8) to the right side.

Unscrew and remove the nuts (9).


Move the condenser (10) forward. Clean the condenser (10) by compressor air.

AIR FILTER Before servicing the filter (1), switch off the blower and close all windows and one door. Slam the final door closed and the resulting back pressure will dislodge most of the loose dirt from the underside of the filter. Remove the filter (1) and clean it by blowing with compressed air not exceeding 2 bar (29 psi). IMPORTANT: make sure you protect your face before using compressed air. Blow the dust from the upper surface through the element to the lower surface. Hold the nozzle at least 300 mm (11.8 in) from the element to prevent damage to the paper pleats. Clean both filter chambers with a damp, lint free cloth. Replace the filter element with the rubber seal uppermost and re-install the covers.

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COMPRESSOR TECHNICAL SPECIFICATIONS Basic compressor specifications Displacement ......................................................................................................................... 155 cm3 (9.46 in3) Weight ............................................................................................................................................ 9.9 kg (22 lb) Oil type ....................................................................................................................................................... SP20 Rotation .............................................................................................................................. CW (Clockwise only) Compressor clutch and pulley air gap ............................................................... 0.9 ÷ 0.8 mm (0.035 ÷ 0.031 in) Belt tension Measure at the widest gap ...... 10 mm (0.40 in) deflection with 1 kg (2.2 lb) force applied midway between the pulleys Speed rating Constant............................................................................................................................................... 6000 rpm Downshift ............................................................................................................................................. 8000 rpm Tightening torque M8 armature retaining nut .....................................................................................17.7 ± 2.9 Nm (13 ± 2.1 lbf·ft) M6 cylinder head screws.......................................................................................13.7 ± 2.9 Nm (10 ± 2.1 lbf·ft) M8 cylinder head screws....................................................................................34.3 ± 4.9 Nm (25.3 ± 3.6 lbf·ft) Clutch dust cover screw ...............................................................................................9 ± 2 Nm (6.6 ± 1.5 lbf·ft) Oil filler plug .......................................................................................................19.6 ± 4.9 Nm (14.5 ± 3.6 lbf·ft)


REMOVAL AND INSTALLATION

REMOVAL Discharge the air conditioning system. Disconnect the wiring harness of the compressor (12) from the wiring harness of the engine. Disconnect tubing to compressor. Remove the washer (7) and the screw (1). Remove the protective guard (13). Remove the screw (11). Remove the nut (14) and the screw (9).

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Remove the washers (5), the nut (6), the screw (2) and the block (8). Remove the screw (1), the washers (3) and the belt tensioner (4). Remove the screw (10), the washers (2) and the compressor (12).

INSTALLATION To install, follow the removal procedure in reverse order. Torque the fastening screws to 40 ÷ 51 Nm (29 ÷ 38 lbf·ft). NOTE: it is recommended that a new receiver/drier assembly is installed after any system component replacement or any repair that requires entry into the system. Drain the oil from the new compressor to be fitted into a clean container, or if the old compressor is to be refitted, obtain a new can of coolant oil. Calculate the amount of oil to be installed and refill the compressor. Reconnect the hoses to the compressor and tighten all screws and hoses.


BELT ADJUSTMENT The compressor drive belt (1) can be tensioned by rotating the idler arm (2). Slacken the idler arm screw and adjust the arm to a belt deflection of 16 mm (0.63 in). Once adjusted re-torque the tension arm screw to 33.9 Nm (25 lbf·ft).

OVERHAUL Before any internal repair is done, drain the oil from the compressor: Remove the oil plug and drain as much oil as possible into a suitable container. Remove the caps (if present) from suction and discharge ports. Drain oil from the section and discharge ports into suitable container while turning the shaft clockwise only with a socket wrench on the armature retaining nut.

Measure and record the amount of oil discharged. Inspect the oil for signs of contamination such as discoloration of foreign material.

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DISASSEMBLY AND ASSEMBLY CLUTCH

1. Screw

6. Cover

2. Dust cover

7. Snap ring

3. Nut

8. Rotor

4. Plate

9. Snap ring

5. Shims

10. Coil

Disassembly All clutch servicing should be done with the compressor removed from the vehicle. Support the compressor. If using a vice, do not hold on to the housing. If a dust cover (2) is present, remove the 3 or 6 screws (1) holding it in place and remove the cover. If auxiliary sheet metal pulley is present, remove the screws holding it in place. Then remove pulley. Attach the tool to the cover in front of the clutch disc and remove the nut (3) using a wrench.


Using the front plate tool and a prybar, hold the clutch plate stationary. Place the screw into the tool and by tightening the screw onto the end of the shaft the front plate will be extracted from the shaft. If shims (5) are above shaft key, remove them now. If shims (5) are below shaft key, the key and bearing dust cover (if present) must be removed before shims can be removed. Remove dust cover (6) (if present). Use caution to prevent distorting cover when removing it. Remove shaft key by tapping loose with a flat blade screwdriver and hammer. Remove shims (5). Use a pointed tool and a small screwdriver to prevent the shims from binding on the shaft. Remove the snap ring (7), remove the shaft key and lift the pulley assembly from the compressor.

Check the rotor assembly (8) for wear and replace the assembly as necessary.

57

Copyright © 58


Remove the field coil wire retaining clip.

Remove the snap ring (9) of the coil.

Lift the coil (10) from the housing and replace as required.


Assembly Install the coil (10), making sure that the wire is located behind the clip on the outside of the body and that the snap ring (9) is located in the groove.

Position the rotor (8) on the housing hub and carefully slide the rotor (8) down the shaft.

Install the snap ring (7).

Reposition the plate (4) and the retaining nut (3). Tighten the nut to the prescribed torque of 18 Nm (13 lbf·ft).

59

Copyright © 60


Check the clearance between the plate (4) and the rotor (8). This should be consistent around the circumference and be between 0.4 ÷ 0.8 mm (0.015 ÷ 0.031 in). NOTE: if the air gap is not consistent, lightly pry up on the counter weighted front plate at the low spots or lightly tap down at the high spots.

If the clearance is not within specification, the shims (5) under the front plate should be added or removed, until the correct clearance is obtained. NOTE: new shims are available in the following sizes: 1.00, 0.50 and 0.13 mm (0.04, 0.02 and 0.005 in).

Reposition the dust cover (2), if present, and torque the 3 or 6 screws (1).


COMPRESSOR

1. Shaft key

6. Gasket

2. Ring

7. Plate

3. Snap ring

8. Head gasket

4. Gasket

9. Cylinder head

5. Plug

10. Screw

Disassembly Remove the armature plate, as detailed in the steps of clutch disassembly. Remove the shaft key (1) and the ring (2) to expose the snap ring (3). Remove the snap ring (3).

Insert the seal (A) remover/installer tool. Turn the tool to engage the slots in the seal. Pull up to remove and discard the seal (4).

61

Copyright © 62


Assembly Thoroughly clean the seal cavity in the hub. Use “lint free” cloth only. Ensure the new shaft seal O-ring is installed onto the seal assembly. Dip the new seal assembly in clean coolant oil and attach to the seal remover/installer tool.

Completely insert the new seal (4). NOTE: if remover/installer tool (A) is not available, position the seal squarely in the hub and tap gently until fully seated.

Install the snap ring (3). If the snap ring has a bevelled edge, this should face outwards.

Install the new ring (2) and push into position.


Position the shims over the shaft and refit the shaft key. Reinstall the plate as described in clutch reassembly.

CYLINDER HEAD Disassembly Drain the coolant oil from the compressor into a clean graduated container. Measure and record the quantity of oil obtained. This information is required during installation of the new or overhauled unit. Remove the six cylinder head screws (10) and using a hide mallet, gently tap the cylinder head (9) free. The use of a gasket scraper may also be required to free the cylinder head from the compressor body.

If the plate (7) and/or cylinder head are to be reused, carefully remove the gasket (8) using a suitable scraper.

63

Copyright © 64


Gently pry the plate (7) free from the cylinder block and remove the gasket (6). Inspect the plate (7) for damage.

Assembly Coat the top of the valve plate with clean coolant oil and reassemble the cylinder head following the removal procedure in reverse order. When installing the gaskets and valve plate ensure they are correctly positioned over the locating pins in the cylinder block. Install the cylinder head screws and tighten using the sequence shown. Torque initially to 20 Nm (15 lbf·ft). When the overhaul is complete add to the compressor a volume of oil equivalent to that drained prior to disassembly, or as the reclaim measured fill.


65

TROUBLESHOOTING TROUBLE Unusually high suction pressure with unusually low discharge pressure.

CAUSE Valve plate test.

ACTION Replace or repair: Broken head or block gasket. Broken or deformed reed valve. Foreign substance under reed valve or gasket.

Unusually low suction and discharge pressure.

Check for low coolant charge.

Replace or repair: Shaft seal leak.

Compressor leak check.

Cylinder head leak. Gasket leak.

Leak check and diagnostic system.

Oil filler plug leak. Cracked cylinder block. Front housing O-ring leak.

Intermittent or inoperative.

Check belt tension.

Replace.

Check clutch air gap.

Adjust air gap.

Check voltage, amperage, coil lead wire of the clutch.

Replace or repair: Broken lead wire. Internal clutch coil defect. System ground (see system manual).

Difficult start.

Shaft turning smoothness test.

Internal compressor failure.

Clutch engaged.

Check compressor mounting components.

Replace or repair.

Check engine components.

Replace or repair.

Check for intermittent or slipping clutch.

Adjust air gap - defective coil.

Check for proper coolant charge.

Recharge and recheck.

Check clutch bearing.

Replace rotor / armature assembly.

Oil level procedure.

Fill to proper level.

Shaft turning smoothness test.

Internal compressor failure.

Remove valve plate and inspect.

Replace or repair: Broken discharge valve reed or retainer. Broken suction valve reed. Broken gasket.

“Chattering” disengaged clutch.

Check air gap.

Replace or repair: Adjust air gap. Defective clutch pulley or front plate.

Copyright © 66

NOTES:


Copyright ©

580T 580ST 590ST 695ST

SECTION 55 - ELECTRIC SYSTEM ELECTRIC DIAGRAMS .................................................................................................................................... 3 ELECTRIC DIAGRAMS - POWERSHUTTLE ROPS (580T mechanical engine) ........................................ 3 ELECTRIC DIAGRAMS - POWERSHUTTLE CAB (580T mechanical engine)......................................... 18 ELECTRIC DIAGRAMS - POWERSHUTTLE CAB (580ST - 590ST electronic engine) ........................... 36 ELECTRIC DIAGRAMS - POWERSHIFT CAB (2WS) .............................................................................. 54 ELECTRIC DIAGRAMS - POWERSHIFT CAB (4WS) .............................................................................. 73 CONTROLS AND INSTRUMENTS ................................................................................................................ 92 FRONT CONTROL PANELS (580T - 580ST - 590ST).............................................................................. 92 FRONT CONTROL PANELS (695ST)....................................................................................................... 94 CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580T mechanical engine).............................. 96 CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580ST - 590ST - 695ST electronic engine) ............. 98 SIDE INSTRUMENT CLUSTER (580T)................................................................................................... 100 SIDE INSTRUMENT CLUSTER (580ST - 590ST - 695ST)..................................................................... 102 ANTI-START SYSTEM ............................................................................................................................ 104 DIAGNOSTIC DISPLAY (580ST - 590ST - 695ST)...................................................................................... 105 SYMBOLS................................................................................................................................................ 107 SETUP MENU ......................................................................................................................................... 108 PROCEDURE ABOUT SELF TEST ........................................................................................................ 109 ON BOARD ERROR CODE RETRIEVAL ............................................................................................... 110 BACKLIGHTING AND DIMMING............................................................................................................. 111 WORK HOURS........................................................................................................................................ 112 OPERATION............................................................................................................................................ 113 WARNING SYSTEM................................................................................................................................ 117 MAINTENANCE....................................................................................................................................... 118 WARNING MESSAGES .......................................................................................................................... 119 STARTING SYSTEM .................................................................................................................................... 125 OPERATION............................................................................................................................................ 125 STARTER MOTOR.................................................................................................................................. 128 TROUBLESHOOTING............................................................................................................................. 133

Copyright © 2

SECTION 55 - ELECTRIC SYSTEM

ALTERNATOR .............................................................................................................................................. 135 TECHNICAL SPECIFICATIONS.............................................................................................................. 135 OPERATION ............................................................................................................................................ 136 TROUBLESHOOTING ............................................................................................................................. 137 BATTERY...................................................................................................................................................... 138 TECHNICAL SPECIFICATIONS.............................................................................................................. 138 OPERATION ............................................................................................................................................ 138 REPLACEMENT ...................................................................................................................................... 139 CHARGE AND ELECTROLYTE LEVEL CHECK .................................................................................... 140 CONNECTING A BOOSTER BATTERY ................................................................................................. 141 BATTERY MASTER SWITCH ................................................................................................................. 141 TROUBLESHOOTING .................................................................................................................................. 142

Copyright © SECTION 55 - ELECTRIC SYSTEM

ELECTRIC DIAGRAMS ELECTRIC DIAGRAMS - POWERSHUTTLE ROPS (580T mechanical engine) FUSES AND RELAYS Fuse no.

Rating

Function

F1B

7.5 A

Engine stop, (+15) anti-theft device, “grid heater”

F1C

10 A

Stop light switch

F2A

15 A

Instrument supply, speed sensor, buzzer

F2C

15 A

Pilot control

F3A

3A

Rear right/front left-side lights, instrument backlighting, air conditioning switch

F3B

3A

Rear left/front right side lights, number plate light

F3C

10 A

Front work light switch, side work light switch, 4x1 bucket handgrip

F4A

5A

Reverse travel buzzer, gearshift lever, forward gear, reverse gear

F4B

10 A

Backhoe hammer button, sensor + bucket level solenoid valve, transmission disconnect button and differential lock button

F4C

10 A

Backhoe attachment lock, backhoe attachment travel lock, rear work light switch

F5A

15 A

Outer front work light relay

F5B

10 A

Low beams

F5C

15 A

Main beams

F6A

7.5 A

Rotating beacon

F6B

7.5 A

(+15) hazard warning light power supply

F6C

7.5 A

Hand hammer, 4WD

F1A

F2B

K5

Low and main beam relay

K6


K7

Outer rear work light relay

K8

Inner front work light relay

K9

Inner rear work light relay

K10 Reverse travel relay K11 Forward travel relay K12 Hazard warning lights

(+30) power supply for hazard lights, antitheft device, horn

F7A F7B F7C F8A

15 A

Outer rear work lights

F8B

15 A

Outer front work lights

F8C

15 A

Inner rear work lights

K1

Forward-reverse travel control relay

K2

Horn relay

K3

Starting relay

K4

Bucket level solenoid valve relay

3

Copyright © 4


COMPONENTS NAME

DESCRIPTION

NAME

DESCRIPTION

A2

Pre-heating for cold start (optional)

G1

Battery

A14

Antitheft unit

G67

Alternator

B4

Air filter blocked switch

H2

Horn

B5

Fuel level sensor

H4

Rear left light

B26

Bucket sensor

H5

Number plate light

B30

Parking brake microswitch

H6

Rear right light

B56

Transmission oil temperature switch

H26

B68

Cold start temperature switch

Backhoe attachment lock warning light (optional)

B69

Air conditioning pressure switch

HA3

Optional buzzer

B70

Engine water temperature sender

H420

Reverse buzzer

B73

Engine oil low pressure switch

K209

Air conditioning relay

B411

Speed sensor

K211

Starting relay

E2

Front left light

K224

Differential lock relay

E3

Front right light

K226

4WD relay

E38

Outer rear work light

K605

Side work light relay

E40

Inner rear work light

M1

Starter motor

E44

Outer front work light

M17

Pneumo-electric seat (optional)

E45

Inner front work light

M64

Air conditioning compressor

E46


P2

Side instrument cluster panel

E47


P125

Speedometer (optional)

E50


S0

Battery master switch

E51


S2

4WD switch

E53

Rotating beacon

S3

Hand hammer switch

E54

Rotating beacon

S5

Ride control switch

E407

Right side work light

S7

Backhoe attachment travel lock switch

E409

Left side work light

S15

Rotating beacon switch

F1

Side work light relay fuse, 15 A

S19

Gearshift lever

F2

Pneumatic seat fuse, 7.5 A

S32

Stop light switch

F3

Ride control, speedometer and valve block fuse, 7.5 A

S33

Stop light switch

S36

Rear hammer button

F4

Quick coupler fuse, 7.5 A

S41

Light-windshield wiper control lever

F208

Air conditioning fuse, 10 A

S42

Warning switch

F500

General fuse

S54

Horn button


NAME

DESCRIPTION

5

CONNECTORS

S100

Quick coupler switch (optional)

NAME

S101

Quick coupler switch (optional)

X1

18-way general line - engine line connector

S126

Lights switch

X2

6-way cold start connector

S135

Vertical backhoe attachment lock switch

X3

1-way engine stop connector

S127

Inner and outer rear work light switch

X4

2-way air filter connector

S141

Inner and outer front work light switch

X6

2-way forward travel connector

S210

Transmission disconnect button

X7

2-way reverse travel connector

S404

Side work light switch

X8

2-way 4WD solenoid valve connector

X10

31-way solenoid valve line - general line connector

X13

17-way general line - front instrument panel connector

X14

11-way antitheft connector

S15.1 Starting panel S205a Transmission disconnect button S205b Differential lock switch ST3

4x1 bucket control lever

Y3

Fuel shut off solenoid valve

Y6

Forward travel solenoid valve

Y7

Reverse speed solenoid valve

Y8

4WD solenoid valve (optional)

Y12

Proportional solenoid valves

Y34

Ride control solenoid valve (optional)

Y35


Y74

Differential lock solenoid valve

Y105

Quick coupler solenoid valve

Y106

Load sensor solenoid valve

Y202

Backhoe attachment travel solenoid valve

Y203

Backhoe attachment lock solenoid valve (optional)

Y206

Bucket level solenoid valve

Y207

Double delivery solenoid valve (optional)

Y209

Backhoe hammer control valve (optional)

DESCRIPTION

X15.1 Starting panel connector X15.2 Starting panel connector X17

4-way pneumo-electric seat connector

X19

Gearshift lever connector

X21

7-way left work light / horn connector

X22

5-way right work light connector

X24

Lock valve interface connector

X26

3-way bucket sensor connector

X27

2-way number plate light connector

X28

4-way rear right light connector

X29

4-way rear left light connector

X31

General line fuse box connector

X34

2-way ride control solenoid valve connector

X35

2-way hand hammer solenoid valve connector

X36

2-way backhoe hammer button connector

X38

2-way rear right work light connector

X40

2-way rear right work light connector (optional)

X44

2-way front right work light connector

Copyright © 6

NAME


DESCRIPTION

X45

2-way front right work light connector (optional)

X46

2-way rear left work light connector (optional)

X47

2-way rear left work light connector

X50

2-way front left work light connector (optional)

X51

2-way front left work light connector

X53

2-way rotating beacon connector

X54


X64

1-way air conditioning compressor connector

X67

3-way alternator connector

X68

3-way engine water temperature switch connector

X69

2-way air conditioning pressure switch connector

NAME

DESCRIPTION

X205

4-way lever button connector

X206

2-way bucket levelling connector

X207

2-way delivery doubling solenoid valve connector

X208

4x1 bucket control lever connector

X209

2-way backhoe hammer solenoid valve connector

X210

2-way clutch disengage button connector

X411

Speed sensor connector

X420

2-way reverse travel buzzer connector

X421

2-way engine stop diode connector

X600


X603

Front instrument panel - quick coupler kit connector

X603/1 Quick coupler kit connector XC1

Control unit 11-way connector

X72

1-way pilot control line connector

XC2


X73

1-way engine oil low pressure switch connector

XC3


XC4


X82


XC5


X83

Relay 2-way connector

XC6


X87

13-way general line - left side instrument cluster line connector

X01

2-way parking brake diode connector

X102

Diode connector

XX

Diode connector

X103

Diode connector

XST2 36-way multifunctional side panel connector

X104

Diode connector

X105

2-way quick coupler solenoid valve connector

X106

Load sensor solenoid valve connector

X125

Front instrument cluster connector

X140

Diode connector

X202

2-way backhoe attachment travel lock solenoid valve connector

X203

2-way backhoe attachment lock solenoid valve connector

X204

2-way horn button connector

Copyright © SECTION 55 - ELECTRIC SYSTEM ENGINE LINE DIAGRAM

7

Copyright © 8


SOLENOID VALVE LINE DIAGRAM


9

Copyright © 10 LIGHT LINE DIAGRAM


Copyright © SECTION 55 - ELECTRIC SYSTEM REAR LIGHT LINE DIAGRAM

11

Copyright © 12 WORK LIGHT LINE DIAGRAM


Copyright © SECTION 55 - ELECTRIC SYSTEM ROTATING BEACON LINE DIAGRAM

13

Copyright © 14


BACKHOE ATTACHMENT QUICK COUPLER LINE DIAGRAM

Quick coupler (optional) See solenoid valve line

Copyright © SECTION 55 - ELECTRIC SYSTEM COLD START DIAGRAM

15

Copyright © 16


SIDE INSTRUMENT CLUSTER

INSTRUMENT

Speedometer

Level fuel

Transmission temperature

Coolant temperature

Battery charge

INPUT

READING

TOLERANCE

INPUT TOLERANCE

CALIBRATION DIRECTION

0 Hz

0 rpm

±3 rpm

N/A

Descending

307 Hz

1000 rpm

N/A

± 60 rpm

Ascending

736 Hz

2400 rpm

N/A

± 60 rpm

Ascending

240 Ohm

Empty

+0/-6 Ohm

230-240 Ohm

Descending

102 Ohm

1/2 Tank

±3 Ohm

98 ÷ 108 Ohm

Descending

33 Ohm

Full

+4/-2 Ohm

33 ÷ 42 Ohm

Ascending

900 Ohm

Point B

+0/-6 °C (32/21.2 °F)

N/A

Descending

114 Ohm

106 °C (223 °F) (Red/green line)

±5 °C (41 °F)

111 ÷ 117 Ohm

Ascending

700 Ohm

Point A

+0/-5 °C (32/23 °F)

N/A

Descending

95 Ohm


±3°

93 ÷ 97 Ohm

Ascending

11 V

Red/green left line

±3°

10.7 ÷ 11.3 V

Descending

15.9 V

Red/green right line

±5°

15.0 ÷ 15.6 V

Ascending


PIN

NAME

17

FUNCTION

1

Ignition

10 V ÷ 16 V INPUT

2

Low oil pressure

Low side switch input

3

Air filter restriction


4

Parking brake


5

Alternator/battery

Alternator D+ input

6

Not used

7

Not used

8

Neutral

High side switch input

9

Seat switch


10

Air conditioning system pressure


11

Not used

12

Driving lights

13

Not used

14

Not used

15

Engine pre-heat

16

Not used

17

Not used

18

Not used

19

Speedometer

20

Level fuel

21

Water temperature

22


23

Not used

24

Driving lights

25

Not used

26

Not used

27

Not used

28

Not used

29

Not used

30

Not used

31

Transmission oil temperature

32

Not used

33

Not used

34

Not used

35

Horn

36

Grounding




Alternator w input



Grounding

Copyright © 18


ELECTRIC DIAGRAMS - POWERSHUTTLE CAB (580T mechanical engine) FUSES AND RELAYS Fuse no.

Rating

Function

F1A

15 A

Rear windshield wiper and washer

F1B

7.5 A

Engine stop, (+15) anti-theft device, “grid heater”

F1C

10 A

Stop light switch

F2A

15 A

Instrument supply, speed sensor, buzzer

F2B

15 A

Air conditioning

F2C

15 A

Pilot control

F3A

3A

Rear right/front left-side lights, instrument backlighting, air conditioning switch

F3B

3A


F3C

10 A


F4A

5A

Reverse travel buzzer, gearshift lever, forward gear, reverse gear

F4B

10 A


F4C

10 A


F5A

15 A


F5B

10 A

Low beams

F5C

15 A

Main beams

F6A

7.5 A

Rotating beacon

F6B

7.5 A


F6C

7.5 A

Hand hammer, 4WD

F7A

10 A

(+30) power supply for hazard lights, antitheft device, horn

F7B

10 A

Electric socket, radio, roof lamp

F7C

6A

Front windshield wiper

F8A

15 A


F8B

15 A


F8C

15 A


K1


K2

Horn relay

K3

Starting relay

K4


K5


K6


K7


K8


K9


K10

Reverse travel relay

K11

Forward travel relay

K12

Hazard warning lights


19

COMPONENTS NAME

DESCRIPTION

NAME

DESCRIPTION

F4

Ride control, speedometer and lock valve fuse, 7.5 A

F208

Air conditioning fuse, 10 A

F500

General fuse

G1

Battery

G67

Alternator

H2

Horn

H4

Rear left light

H5

Number plate light

H6

Rear right light

H18

Roof lamp

H26


Speed sensor

HA3

Optional buzzer

BS1

Right speaker (optional)

H420

Reverse buzzer

BS2

Left speaker (optional)

K209

Air conditioning relay

E2

Front left light

K211

Starting relay

E3

Front right light

K224


E38


K226

4WD relay

E40


K230

Hand hammer relay

E44


K605


E45


M1

Starter motor

E46


M17

Pneumo-electric seat (optional)

E47


M39

Rear windshield wiper motor

E50


M41

Blower motor (optional)

E51


M49

Front windshield wiper motor

E55

Current intake illumination

M56

Front windshield washer pump

E406

Rotating beacon

M57

Rear windshield washer pump

E407


M64


E409


P2


E412

Rotating beacon

P125


F1


S0


F2

Quick coupler fuse, 7.5 A

S2

4WD switch

F3

Pneumo-electric seat fuse, 7.5 A

S3

Hand hammer switch

A2

Pre-heating for cold start (optional)

A14

Antitheft unit

B4


B5

Fuel level sensor

B26

Bucket sensor

B30


B53

Radio (optional)

B65


B68

Cold start temperature switch

B69


B70

Engine water temperature sender

B73

Engine oil low pressure switch

B411

Copyright © 20


NAME

DESCRIPTION

NAME

DESCRIPTION

S5

Ride control switch

Y74


S15


Y105


S19

Gearshift lever

Y106


S32

Stop light switch

Y202


S33

Stop light switch

Y203

S34

Port left microswitch


S35

Port right microswitch

Y206


S36

Rear hammer button

Y207


S41


Y209


S42

Warning switch

S100

Quick coupler A switch (optional)

S101

Quick coupler B switch (optional)

S126

Lights switch

S135


S137

Inner and outer rear work light switch

S138

Windshield wiper + pump switch

S140

Backhoe attachment travel lock switch

S141

Inner and outer front work light switch

S210

Clutch disconnect button

S404


CONNECTORS NAME X1


X2


X3


X4


X6


X7


X8


X10


X12

9-way general line - upper cab line connector

X13


X14


S15.1 Starting panel S205a Clutch disconnect button S205b Differential lock switch ST3


X55

Current intake

Y3

Fuel shut off solenoid valve

Y6


Y7


Y8

4WD solenoid valve (optional)

Y12


Y34


Y35


DESCRIPTION



X19


X21

7-way left light / horn connector

X22

5-way right light connector


NAME

DESCRIPTION

X24


X26


X27


X28


X29


X31


X34


X35


X36


X38


X39

4-way rear windshield wiper connector

X40


X44


X45


X46


NAME

21

DESCRIPTION

X69


X72


X73

1-way engine oil low pressure switch connector

X82


X83

Relay 2-way connector

X87


X88

9-way general line - right side instrument cluster line connector

X102

Diode connector

X103

Diode connector

X104

Diode connector

X105


X106


X110

2-way air conditioner connector

X111


X125


X47


X140

Diode connector

X49

6-way front windshield wiper connector

X202

X50



X203


X204

2-way horn button on pilot control connector

X205


X206


X207


X208


X209


X210


X406


X411


X412


X51


X53

8-way radio connector (brown)

X54

8-way radio connector (black)

X55

2-way electric socket connector

X56

2-way front windshield washer connector

X57

2-way rear windshield washer connector

X64


X67


X68

3-way engine water temperature switch connector

Copyright © 22

NAME


DESCRIPTION

X420


X421


X600


X603


X603/1 Quick coupler kit connector XC1


XC2


XC3


XC4


XC5


XC6


X01


XX

Diode connector

XST2 36-way multifunctional side panel connector


23

Copyright © 24




25



Copyright © SECTION 55 - ELECTRIC SYSTEM REAR LIGHT LINE DIAGRAM

27



Copyright © SECTION 55 - ELECTRIC SYSTEM WINDSHIELD WIPER - WASHER LINE DIAGRAM

29

Copyright © 30 CAB LINE DIAGRAM


Copyright © SECTION 55 - ELECTRIC SYSTEM AIR CONDITIONER DIAGRAM

S

Evaporator box

S45

11-way connector

1

3rd speed relay

9

Potentiometer

2

Fuse 25 A

10

Speed switch

3

Blower motor

11

Temperature switch

4

1 and 2 speed resistor

12

12 V light

5

Electric cock

A

2-way waterproof connection

X111

9-way connector

B


X110

2-way power connector

31

Copyright © 32



See “Solenoid valve line” Quick coupler (optional)

Copyright © SECTION 55 - ELECTRIC SYSTEM COLD START LINE DIAGRAM

33

Copyright © 34



INSTRUMENT

Speedometer

Level fuel


Coolant temperature

Battery charge

INPUT

READING

TOLERANCE

INPUT TOLERANCE

CALIBRATION DIRECTION

0 Hz

0 rpm

±3 rpm

N/A

Descending

307 Hz

1000 rpm

N/A

± 60 rpm

Ascending

736 Hz

2400 rpm

N/A

± 60 rpm

Ascending

240 Ohm

Empty

+0/-6 Ohm

230-240 Ohm

Descending

102 Ohm

1/2 Tank

±3 Ohm

98 ÷ 108 Ohm

Descending

33 Ohm

Full

+4/-2 Ohm

33 ÷ 42 Ohm

Ascending

900 Ohm

Point B

+0/-6 °C (32/21.2 °F)

N/A

Descending

114 Ohm


±5 °C (41 °F)

111 ÷ 117 Ohm

Ascending

700 Ohm

Point A

+0/-5 °C (32/23 °F)

N/A

Descending

95 Ohm


±3°

93 ÷ 97 Ohm

Ascending

11 V

Red/green left line

±3°

10.7 ÷ 11.3 V

Descending

15.9 V

Red/green right line

±5°

15.0 ÷ 15.6 V

Ascending


PIN

NAME

35

FUNCTION

1

Ignition

10 V ÷ 16 V INPUT

2

Low oil pressure


3

Air filter restriction


4

Parking brake


5

Alternator/battery

Alternator D+ input

6

Not used

7

Not used

8

Neutral


9

Seat switch


10

Air conditioning system pressure


11

Not used

12

Driving lights

13

Not used

14

Not used

15

Engine pre-heat

16

Not used

17

Direction

18

Not used

19

Speedometer

20

Level fuel

21

Water temperature

22


23

Not used

24

Driving lights

25

Not used

26

Not used

27

Not used

28

Not used

29

Not used

30

Not used

31

Transmission oil temperature

32

Not used

33

Not used

34

Not used

35

Horn

36

Grounding




Alternator w input



Grounding

Copyright © 36


ELECTRIC DIAGRAMS - POWERSHUTTLE CAB (580ST - 590ST electronic engine) FUSES AND RELAYS Fuse no.

Rating

Function

F1A

15 A


F1B

7.5 A

(+15) anti-theft device, (+15) ECU power supply

F1C

10 A

Stop light switch

F2A

15 A

Instrument power supply, pneumo-electric seat, speed sensor, start up

F2B

15 A

Air conditioning

F2C

15 A

Pilot control

F3A

3A

Rear right/front left side light, instrument backlighting

F3B

3A


F3C

10 A


F4A

5A

Forward travel, reverse travel, reverse travel buzzer, gearshift control

F4B

10 A


F4C

10 A


F5A

15 A


F5B

10 A

Low beams

F5C

15 A

Main beams

F6A

7.5 A

Rotating beacon

F6B

7.5 A


F6C

7.5 A

Hand hammer, 4WD

F7A

10 A

(+30) power supply for hazard warning lights, horn

F7B

10 A


F7C

6A


F8A

15 A


F8B

15 A


F8C

15 A


K1


K3

Starting relay

K4


K5


K6


K7


K8


K9


K10

Reverse travel relay

K11

Forward travel relay

K12

Direction indicator flashing


37

COMPONENTS NAME

DESCRIPTION

NAME

DESCRIPTION

F1

Diagnostic socket +30 fuse

F2


F3

+30 switch and +30 instrument panel fuse

F4

Quick coupler fuse

F5

Ride control, front panel and lock valve fuse, 7.5 A

F112

Air conditioning fuse

F113

Water in fuel sensor fuse

F500

General fuse

F602

Engine control unit fuse

G1

Battery

G67

Alternator

H2

Horn

H7

Reverse buzzer

H26


Front left light

H606

Buzzer

E3

Front right light

K102

Starting relay

E18

Roof lamp

K103

Starting

E27

Number plate light

K104

Starter motor relay

E28

Rear left light

K105

Air conditioning compressor relay

E29

Rear right light

K224


E38


K226

4WD relay

E40


K230

Hand hammer relay

E44


K605


E45


M1

Starter motor

E46


M39


E47


M41


E50


M49


E51


M56

Front windshield wiper pump

E55

Cigarette lighter

M57

Rear windshield wiper pump

E406

Rotating beacon

M64


E407


P1


E409


P125


E412

Rotating beacon

A14

Antitheft unit

A53

Radio (optional)

A106

Engine control unit

B4


B5

Fuel level sensor

B25

Foot accelerator

B26

Bucket sensor

B30


B66


B69


B107

Water in fuel sensor

B411

Speed sensor

B608

Hand accelerator

BS1

Left speaker (optional)

BS2

Right speaker (optional)

E2

Copyright © 38


NAME

DESCRIPTION

NAME

DESCRIPTION

R2

Grid heater (optional)

X72

Pilot control interface connector

S2

4WD switch

X201

Accelerator knob

S3

Hand hammer switch

Y6


S5

Ride control switch

Y8

4WD solenoid

S9

Lights switch

Y12


S15


Y34


S15.1 Starting panel

Y35


S32

Stop light switch

Y74


S33

Stop light switch

Y105


S34


Y106


S35


Y200


S36

Rear hammer button (optional)

Y202


S41


Y203

S42

Warning switch


S100


Y206


S101


Y207


S132

Gearshift lever

Y209


S135


S136

Menu scroll switch

S137

Rear work light switch

S138


S139

Display enter switch

S140

Rear travel switch

S141

Front work light switch

S144

Rear horn button

S210

Transmission disconnect button

S205a Clutch disconnect button S205b Differential lock switch S604


SB1


ST3


X17

Seat (optional)

X21

Diagnostic socket

X55

Auxiliary 12 V socket

CONNECTORS NAME

DESCRIPTION

X1


X2


X3


X4


X6


X7


X8


X10


X12



NAME

DESCRIPTION

X13


X14


X15.1 Starting panel connector X15.2 Starting panel connector

NAME

39

DESCRIPTION

X51


X53


X54


X55


X56


X57


X64


X17


X19


X22

5-way right work light connector

X24


X67


X25

Foot accelerator connector

X69

X26



X27


X72


X28


X87


X29


X88

X31



X34


X102

Diode connector

X103

Diode connector

X35


X104

Diode connector

X36


X105


X38


X106

Engine control unit connector

X39


X106


X40


X107

Water in fuel connector

X41

2-way blower connector (optional)

X110


X43


X111


X44


X125


X45


X140

Diode connector

X200


X46


X47


X49


X50


X201.s Accelerator knob connector X201.p Accelerator knob connector X202


X203


X204


Copyright © 40

NAME


DESCRIPTION

X205


X206


X207


X208


X209


X210


X220

Air conditioning connector

X401


X406


X411


X412


X420


X421


X603


X603/1 Quick coupler kit connector X606

Buzzer connector

X607

7-way left light - horn connector

X608

Manual accelerator connector

XC1


XC2


XC3


XC4


XC5


XC6


X01


XX

Diode connector

XST1 36-way multifunctional side panel connector XST2 26-way multifunctional side panel connector


41

Copyright © 42




43



Copyright © SECTION 55 - ELECTRIC SYSTEM REAR WORK LIGHT LINE DIAGRAM

45



Copyright © SECTION 55 - ELECTRIC SYSTEM WINDSHIELD WIPER AND WASHER LINE DIAGRAM

47

Copyright © 48 CAB LINE DIAGRAM


Copyright © SECTION 55 - ELECTRIC SYSTEM AIR CONDITIONING LINE DIAGRAM

S

Evaporator box

S45

11-way connector

1

3rd speed relay

9

Potentiometer

2

Fuse 25 A

10

Speed switch

3

Blower motor

11

Temperature switch

4


12

12 V light

5

Electric cock

A


X111

9-way connector

B


X110


49

Copyright © 50





51

Copyright © 52



INSTRUMENT

Level fuel

Low fuel level (lamp) Speedometer

Coolant temperature

Battery charge


INPUT

READING

TOLERANCE

320 Ohm

Empty - minimum reading

+0/-2 Ohm

185 Ohm

Right - edge of red band

± 3 Ohm (Ref)

6.5 Ohm

Full - maximum reading

+4/-0 Ohm

193 Ohm

ON

± 5 Ohm

185 Ohm

OFF

± 5 Ohm

Can message

0 - 3000 rpm

± 50 rpm

Can message

Minimum reading 65 °C (149 °F)

± 3 °C (± 37.4 °F)

Can message

Left edge of red band 106 °C (223 °F)

± 2 °C (± 35.6 °F)

Can message

Maximum reading 112 °C (234 °F)

± 3 °C (± 37.4 °F)

11 V

Right edge of lower red band

± 3°

16 V

Edge of upper red band

± 3°

385 Ohm


± 3 °C (± 37.4 °F)

149 Ohm


± 2 °C (± 35.6 °F)

112 Ohm


± 3 °C (± 37.4 °F)


CN1 PIN

FUNCTION

53

CN2 NOTE

1

Not used

2

Key on power

Wake up

3

In gear input

Digital input

4

Driving lights

Digital input

5

Front work lights

Digital input

6

Rear work lights

Digital input

7

Not used

8

Not used

9

Not used

10

Air conditioning pressure

Digital input

11

Display switch input

Digital input

12

Menu confirmation switch input

Digital input

13

UP switch input

14

PIN

FUNCTION

NOTE

1

Keep alive power

2

Not used

3

Can Bus line input

4

Can Bus line input

5

Not used

6

Buzzer

7

Starter motor lock

8

Not used

9

Not used

10

Not used

11

Not used

Digital input

12

Not used

DOWN switch input

Digital input

13

Fuel level gauge

Resistance

15

Cranking

Digital input

14

Thermistor

16

Clogged air filter

Digital input


17

Not used

15

Not used

18

Parking brake

16

Foot accelerator

0.5 ÷ 4.5 V

19

Not used

17

Accelerator knob

0.5 ÷ 4.5 V

20

Minimum confirmation switch

Digital input

18

Foot accelerator

Output monitored for diagnostics

21

Decelerator button

Digital input

19

Accelerator knob


22

Not used

20

Foot accelerator

23

Not used

21

Accelerator knob

24

Not used

22

Not used

25

Transmission oil pressure

23

Not used

26

Not used

24

Alternator excitation

25

Not used

26

Ground

Digital input

Digital input

Need to fuse at 1 ampere without disconnect

40 Ohm relay = 300 mA

Digital input

Copyright © 54


ELECTRIC DIAGRAMS - POWERSHIFT CAB (2WS) FUSES AND RELAYS Fuse no.

Rating

Circuit

K3

Starting relay

F1A

15 A


K4


F1B

7.5 A

Engine stop, (+15) anti-theft device, (+25) ECU power supply

K5


K6


F1C

10 A

Trax controller + 4WD, automatic/manual switch for transmission disconnection

K7


K8


15 A

Side instrument power supply, pneumoelectric seat, start up

F2A

K9


K10

Optional

F2B

15 A

Air conditioning K11

Direction indicator flashing relay

F2C

15 A

Pilot control

F3A

3A


F3B

3A


F3C

10 A


F4A

7.5 A

Stop lights, Trax controller

F4B

10 A

Backhoe hammer button, bucket level solenoid valve + sensor, transmission disconnect button

F4C

10 A

Backhoe attachment lock, backhoe attachment travel lock, rear work light switches

F5A

15 A


F5B

10 A

Low beams

F5C

15 A

Main beams

F6A

15 A

Rotating beacon

F6B

7.5 A


F6C

7.5 A

(+15) gearshift control supply

F7A

10 A

(+30) power supply for hazard lights, horn, anti-theft device,

F7B

10 A


F7C

6A


F8A

15 A


F8B

15 A


F8C

15 A



55

COMPONENTS NAME

DESCRIPTION

NAME

DESCRIPTION

E407


E409


E412

Rotating beacon

F1


F2


F3


F4

Quick coupler fuse

F5

Ride control, front instrument cluster and lock valve fuse, 7.5 A

F112


F113


F500

General fuse

F602


G1

Battery

G67

Alternator

H2

Horn

H7

Reverse buzzer

H26


Front left light

H606

Buzzer

E3

Front right light

K14

Transmission disconnect relay

E18

Roof lamp

K102

Relay for start signal from the control unit

E27

Number plate light

K103

Starting

E28

Rear left light

K104

Starter motor relay

E29

Rear right light

K105


E38


K227

4WD relay

E40


K230

Hand hammer relay

E44


K605


E45


M1

Starter motor

E46


M39


E47


M41


E50


M49


E51


M56


E55

Cigarette lighter

M57


E406

Rotating beacon

A14

Antitheft unit

A53

Radio (optional)

A106

Engine control unit

A401

Transmission control unit

B4


B5

Fuel level sensor

B25

Foot accelerator

B26

Bucket sensor

B30


B66


B69


B107


B108

Transmission temperature sensor

B109

Pressure switch

B112

Speed sensor

B608

Hand accelerator

BS1

Left speaker

BS2

Right speaker

E2

Copyright © 56


NAME

DESCRIPTION

NAME

DESCRIPTION

M64


ST3


P125


X17

Seat (optional)

R2


X55

Diagnostic socket

S2

4WD switch

X72


S3

Hand hammer switch

X201

Accelerator knob

S5

Ride control switch

X607

Diagnostic

S9

Lights switch

Y12


S15


Y34


S15.1 Start switch

Y35

Hand hammer solenoid valve

S29

Front horn switch

Y100


S32

Stop light switch

Y101


S33

Stop light switch

Y102

PWM 1/3 solenoid valve

S34


Y103

PWM 1/3 - PWM 2/4 solenoid valve

S35


Y104

S13 - PWM 1/3 solenoid valve

S36

Hand hammer button (optional)

Y105


S41


Y106


S42

Warning switch

Y113

4WD solenoid

S48

Manual-auto switch

Y114


S100


Y202


S101


Y203

S135



S136

Menu scroll switch

Y206


S137


Y207


S138


Y209


S139


S140

Rear travel switch

S141


S144

Rear horn button

S205a Clutch disconnect button S205b Differential lock switch S400

Gearshift lever

S604


SB1


ST1



57

CONNECTORS NAME

DESCRIPTION

NAME

DESCRIPTION

X41


X43


X44



X45


X10


X46


X12


X47


X13


X49


X50


X51


X53


X54


X55


X56


X57


X64


X67


X69


X72


X87


X1


X2


X4


X7

X14




X21


X22


X23

Front instrument panel line - general line interface connector

X24


X25


X26


X27


X28


X29


X31


X88

X34



X102

Diode connector

X103

Diode connector

X104

Diode connector

X105


X35


X36


X38


X39


X106


X40


X106


X107


Copyright © 58

NAME


DESCRIPTION

NAME

DESCRIPTION

X110


X600


X111


X603

X125



X201.s Accelerator knob connector X201.p Accelerator knob connector X202


X203


X204


X205


X206


X207


X208


X209


X210


X220


X226

Connector (optional)

X400


X401

Transmission control unit connector

X402

Transmission line - “Carraro” transmission line connector

X403


X404

Transmission line - front instrument panel line connector

X406

Transmission line connector

X406

Rotating beacon connector

X408

General line - front instrument panel line connector

X409


X412


X420


X421


X603/1 Quick coupler kit connector X606

Buzzer connector

X608

Manual accelerator connector

XC1


XC2


XC3


XC4


XC5


XC6


XX

Diode connector



59

Copyright © 60


TRANSMISSION CONTROL UNIT LINE DIAGRAM

Copyright © SECTION 55 - ELECTRIC SYSTEM SOLENOID VALVE LINE DIAGRAM

61

Copyright © 62


Copyright © SECTION 55 - ELECTRIC SYSTEM LIGHT LINE DIAGRAM

63

Copyright © 64


REAR WORK LIGHT LINE DIAGRAM

Copyright © SECTION 55 - ELECTRIC SYSTEM WORK LIGHT LINE DIAGRAM

65

Copyright © 66


WINDSHIELD WIPER AND WASHER LINE DIAGRAM

Copyright © SECTION 55 - ELECTRIC SYSTEM CAB LINE DIAGRAM

67

Copyright © 68


AIR CONDITIONING LINE DIAGRAM

S

Evaporator box

S45

11-way connector

1

3rd speed relay

9

Potentiometer

2

Fuse 25 A

10

Speed switch

3

Blower motor

11

Temperature switch

4


12

12 V light

5

Electric cock

A


X111

9-way connector

B


X110


Copyright © SECTION 55 - ELECTRIC SYSTEM BACKHOE ATTACHMENT QUICK COUPLER LINE DIAGRAM


69

Copyright © 70 COLD START LINE DIAGRAM



71


INSTRUMENT

Level fuel


Coolant temperature

Battery charge


INPUT

READING

TOLERANCE

320 Ohm


+0/-2 Ohm

185 Ohm


± 3 Ohm (Ref)

6.5 Ohm


+4/-0 Ohm

193 Ohm

ON

± 5 Ohm

185 Ohm

OFF

± 5 Ohm

Can message

0 - 3000 rpm

± 50 rpm

Can message


± 3 °C (± 37.4 °F)

Can message


± 2 °C (± 35.6 °F)

Can message


± 3 °C (± 37.4 °F)

11 V


± 3°

16 V


± 3°

385 Ohm


± 3 °C (± 37.4 °F)

149 Ohm


± 2 °C (± 35.6 °F)

112 Ohm


± 3 °C (± 37.4 °F)

Copyright © 72


CN1 PIN

FUNCTION

CN2 NOTE

1

Not used

2

Key on power

Wake up

3

In gear input

Digital input

4

Driving lights

Digital input

5

Front work lights

Digital input

6

Rear work lights

Digital input

7

Not used

8

Not used

9

Not used

10


Digital input

11


Digital input

12


Digital input

13

UP switch input

14

PIN

FUNCTION

NOTE

1

Keep alive power

2

Not used

3

Can Bus line input

4

Can Bus line input

5

Not used

6

Buzzer

7

Starter motor lock

8

Not used

9

Not used

10

Not used

11

Not used

Digital input

12

Not used

DOWN switch input

Digital input

13

Fuel level gauge

Resistance

15

Cranking

Digital input

14

Thermistor

16

Clogged air filter

Digital input


17

Not used

15

Not used

18

Parking brake

16

Foot accelerator

0.5 ÷ 4.5 V

19

Not used

17

Accelerator knob

0.5 ÷ 4.5 V

20


Digital input

18

Foot accelerator


21

Decelerator button

Digital input

19

Accelerator knob


22

Not used

20

Foot accelerator

23

Not used

21

Accelerator knob

24

Not used

22

Not used

25


23

Not used

26

Not used

24


25

Not used

26

Ground

Digital input

Digital input



Digital input

Copyright © SECTION 55 - ELECTRIC SYSTEM ELECTRIC DIAGRAMS - POWERSHIFT CAB (4WS) RELAY FUSES Fuse no.

Rating

Function

K3

Starting relay

F1A

15 A


K4


F1B

7.5 A

Engine stop, (+15) anti-theft device, (+15) ECU power supply, starter switch key

K5


K6


F1C

10 A

Trax controller + 4WD, automatic/manual switch

K7


K8


15 A

Side instrument power supply, pneumoelectric seat, start up

F2A

K9


K10

Optional relay

F2B

15 A

Air conditioning K10

Direction indicator flashing relay

F2C

15 A

Pilot control

F3A

3A


F3B

3A


F3C

10 A


F4A

7.5 A

Stop lights, Trax controller

F4B

10 A

Backhoe hammer button, bucket level solenoid valve + sensor, transmission disconnect button

F4C

10 A


F5A

15 A


F5B

10 A

Low beams

F5C

15 A

Main beams

F6A

15 A

Rotating beacon

F6B

7.5 A

(+15) hazard warning lights

F6C

7.5 A

(+15) gearshift control supply

F7A

10 A

(+30) hazard warning lights, horn, antitheft device

F7B

10 A


F7C

6A


F8A

15 A


F8B

15 A


F8C

15 A


73

Copyright © 74


COMPONENTS NAME

DESCRIPTION

NAME

DESCRIPTION

E55

Cigarette lighter lamp

E406

Rotating beacon

E407


E409


E412

Rotating beacon

F1


F2


F3


F4

Quick coupler fuse

F5

Ride control, front instrument cluster and lock valve fuse, 7.5 A

F112


F113


F500

General fuse

F602


G1

Battery

G67

Alternator

H2

Horn

H7

Reverse buzzer

H26


Front left light

H606

Buzzer

E3

Front right light

K14

Transmission cut-off relay

E18

Roof lamp

K102

Relay for start signal from the control unit

E27

Number plate light

K103

Starting

E28

Rear left light

K104

Starter motor relay

E29

Rear right light

K105


E38


K227

4WD relay

E40


K230

Hand hammer relay

E44


K605


E45


M1

Starter motor

E46


M39


E47


M41


E50


M49


E51


A14

Antitheft unit

A53

Radio (optional)

A105

Engine control unit

A401

Transmission control unit

B4


B5

Fuel level sensor

B25

Foot accelerator

B26

Bucket sensor

B30


B66


B69


B97

Front axle sensor

B98

Rear axle sensor

B107


B108


B109

Pressure switch

B112

Speed sensor

B608

Accelerator knob

BS1

Left speaker

BS2

Right speaker

E2


NAME

DESCRIPTION

NAME

75

DESCRIPTION

M56


SB1


M57


ST1


M64


ST3


P125


X17

Seat (optional)

R2


X55

Diagnostic socket

S2

4WD switch

X72


S3

Hand hammer switch

X201

Accelerator knob

S5

Ride control switch

X607

Diagnostic

S9

Lights switch

Y12


S15


Y34


S15.1 Start switch

Y35

Hand hammer solenoid valve

S29

Front horn switch

Y91

Crab steering solenoid valve

S32

Stop light switch

Y92

Round steering solenoid valve

S33

Stop light switch

Y93

4WS steering solenoid valve

S34


Y94

2WS steering solenoid valve

S35


Y100


S36

Hand hammer button (optional)

Y101


S41


Y102

PWM 1/3 solenoid valve

S42

Warning switch

Y103

PWM 1/3 - PWM 2/4 solenoid valve

S47

Steering selector

Y104

S13 - PWM 1/3 solenoid valve

S48

Manual-auto switch

Y105


S100


Y106


S101


Y113

4WD solenoid

S135


Y114


S136

Menu scroll switch

Y202


S137


Y203

S138



S139


Y206


S140

Rear travel switch

Y207


S141


Y209


S144

Rear horn button

S205a Clutch disconnect button S400

Gearshift lever

S404


Copyright © 76


CONNECTORS NAME

DESCRIPTION

X1


X2


X4


X5

Fuel level indicator connector

X7


X10


X12


X13


X14




X21


X22


X23

Front instrument panel line - general line interface connector

X24


X25


X26


X27


X28


X29


X31


X34


X35


X36


X38


X39


X40


NAME

DESCRIPTION

X41


X43


X44


X45


X46


X47


X49


X50


X51


X53


X54


X55


X56


X57


X64


X67


X69


X72


X87


X88



NAME

DESCRIPTION

NAME

77

DESCRIPTION

X91

Crab steering solenoid valve connector

X400


X92

Round steering solenoid valve connector

X401

Transmission control unit connector

X93

4WS steering solenoid valve connector

X402

X94

2WS steering solenoid valve connector


X95

Steering control unit connector

X403


X96

Steering control unit connector

X404

X97

Front axle connector


X98

Rear axle connector

X406

Transmission line connector

X102

Diode connector

X406

Rotating beacon connector

X103

Diode connector

X408

X104

Diode connector

General line - front instrument panel line connector

X105


X409


X106


X412


X106


X420


X107


X421


X110

Air conditioner connector

X600


X111

Air conditioner connector

X603


X125


X603/1 Quick coupler kit connector

X201.s Accelerator knob connector

X606

Buzzer connector

X201.p Accelerator knob connector

X608

Accelerator knob connector

X202


XC1


X203


XC2


XC3


XC4


XC5


XC6


XX

Diode connector

X204


X205


X206


X207


X208


X209


X210


X220


X226

Connector (optional)


Copyright © 78 ENGINE LINE DIAGRAM


Copyright © SECTION 55 - ELECTRIC SYSTEM TRANSMISSION CONTROL UNIT LINE DIAGRAM

79

Copyright © 80


4WS STEERING LINE DIAGRAM

Copyright © SECTION 55 - ELECTRIC SYSTEM SOLENOID VALVE LINE DIAGRAM

81

Copyright © 82


Copyright © SECTION 55 - ELECTRIC SYSTEM LIGHT LINE DIAGRAM

83

Copyright © 84


REAR WORK LIGHT LINE DIAGRAM

Copyright © SECTION 55 - ELECTRIC SYSTEM WORK LIGHT LINE DIAGRAM

85

Copyright © 86


WINDSHIELD WIPER AND WASHER LINE DIAGRAM

Copyright © SECTION 55 - ELECTRIC SYSTEM CAB LINE DIAGRAM

87

Copyright © 88





89

Copyright © 90



INSTRUMENT

Level fuel


Coolant temperature

Battery charge


INPUT

READING

TOLERANCE

320 Ohm


+0/-2 Ohm

185 Ohm


± 3 Ohm (Ref)

6.5 Ohm


+4/-0 Ohm

193 Ohm

ON

± 5 Ohm

185 Ohm

OFF

± 5 Ohm

Can message

0 - 3000 rpm

± 50 rpm

Can message


± 3 °C (± 37.4 °F)

Can message


± 2 °C (± 35.6 °F)

Can message


± 3 °C (± 37.4 °F)

11 V


± 3°

16 V


± 3°

385 Ohm


± 3 °C (± 37.4 °F)

149 Ohm


± 2 °C (± 35.6 °F)

112 Ohm


± 3 °C (± 37.4 °F)


CN1 PIN

FUNCTION

91

CN2 NOTE

1

Not used

2

Key on power

Wake up

3

In gear input

Digital input

4

Driving lights

Digital input

5

Front work lights

Digital input

6

Rear work lights

Digital input

7

Not used

8

Not used

9

Not used

10


Digital input

11


Digital input

12


Digital input

13

UP switch input

14

PIN

FUNCTION

NOTE

1

Keep alive power

2

Not used

3

Can Bus line input

4

Can Bus line input

5

Not used

6

Buzzer

7

Starter motor lock

8

Not used

9

Not used

10

Not used

11

Not used

Digital input

12

Not used

DOWN switch input

Digital input

13

Fuel level gauge

Resistance

15

Cranking

Digital input

14

Thermistor

16

Clogged air filter

Digital input


17

Not used

15

Not used

18

Parking brake

16

Foot accelerator

0.5 ÷ 4.5 V

19

Not used

17

Accelerator knob

0.5 ÷ 4.5 V

20


Digital input

18

Foot accelerator


21

Decelerator button

Digital input

19

Accelerator knob


22

Not used

20

Foot accelerator

23

Not used

21

Accelerator knob

24

Not used

22

Not used

25


23

Not used

26

Not used

24


25

Not used

26

Ground

Digital input

Digital input



Digital input

Copyright © 92


CONTROLS AND INSTRUMENTS FRONT CONTROL PANELS (580T - 580ST - 590ST)

1. 2WD/4WD SWITCH This switch is used to engage or disengage the 4WD function. This switch has two positions: - First position (powershuttle), by pushing button on the left : rear wheel drive and braking on rear wheels (for all gears) (lamp off). - First position (powershift), by pushing button on the left : rear wheel drive with braking only on rear wheels (only in first and second gear) (lamp off); four wheel drive and braking (in third and fourth gear) (lamp on). - Second position (by pushing button on the right ): 4 wheel drive and braking on 4 wheels (lamp on).

2. HAND-HELD AUXILIARY HYDRAULIC ATTACHMENT SWITCH (Optional) This switch has two positions: - The first position is OFF. - The second position is ON and enables the auxiliary hydraulic attachments. 3. LOADER ATTACHMENT SWITCH (Optional) 4. LOADER ATTACHMENT LOCKING SWITCH (Optional) When operated, this switch prevents any movement of the loader attachment during travel. 5. ROTATING BEACON SWITCH This switch is used to turn the rotating beacon on or off.

Copyright © SECTION 55 - ELECTRIC SYSTEM 6. ROLL-OVER PROTECTION SWITCH (Optional) This switch is used to engage or disengage the roll-over protection device. When the operator is about to start working with the backhoe attachment in conditions which could cause the machine to roll over, he/she must activate the roll-over protection device by pressing the switch (ON position and lamp turned on). In this condition, the audible alarm will sound by means of the buzzer when the pressure switch, installed on the backhoe attachment boom cylinder, detects a pressure exceeding the following values: 2WS = 116 bar (17 psi) 4WS = 126.5 bar (18 psi) 7. “GLIDE RIDE” SWITCH (Optional) The “glide ride” system control improves the machine comfort during travel, regardless of the type of terrain and with the loader bucket full or empty. It reduces forward and rearward pitching when moving rearwards or forwards and when carrying loads, at the same time increasing productivity and operator comfort. It also reduces impact forces to the machine during operation. Do not use this system while operating the loader attachment.

WARNING Never operate the “glide ride” system control when the loader arm and loader bucket are maintaining the front of the machine raised off the ground. The machine could fall and cause serious or fatal injury. 8. MANUAL MODE SELECTION SWITCH (Powershift transmission) In situations where manual gearshifting (up or downshift) is required, the automatic gearshift of the powershift transmission can be overridden by means of this switch. NOTE: changing gears up or down must always be done using the powershift transmission lever. When the manual mode is no longer required, place the switch back to the OFF position to return to automatic gearshifting.

93

9. HORN BUTTON This button operates the warning horn. 10. HAZARD LIGHT SWITCH Press the control down to locked position. The direction indicators and the control will flash simultaneously. Press the control down again to turn off the direction indicators and the lamp.

Copyright © 94


FRONT CONTROL PANELS (695ST)

1. 2WD/4WD SWITCH This switch is used to engage or disengage the 4WD function. This switch has two positions: - First position (powershuttle), by pushing button on the left : rear wheel drive and braking on rear wheels (for all gears) (lamp off). - First position (powershift), by pushing button on the left : rear wheel drive with braking only on rear wheels (only in first and second gear) (lamp off); four wheel drive and braking (in third and fourth gear) (lamp on). - Second position (by pushing button on the right ): 4 wheel drive and braking on 4 wheels (lamp on).

2. HAND-HELD AUXILIARY HYDRAULIC ATTACHMENT SWITCH (Optional) This switch has two positions: - The first position is OFF. - The second position is ON and enables the auxiliary hydraulic attachments. 3. LOADER ATTACHMENT LOCKING SWITCH (Optional) When operated, this switch prevents any movement of the loader attachment during travel. 4. STEER MODE SWITCH This switch has a locking cover and is used to select “Road”, “4 wheel steer” or “Crab steer”. This switch has three positions: - Position (a) = Road - Position (b) = 4 wheel steer - Position (c) = Crab steer IMPORTANT: before undertaking any road travel, select “Road” mode and fold back the cover to lock the switch in this position.

Copyright © SECTION 55 - ELECTRIC SYSTEM 5. ROTATING BEACON SWITCH This switch is used to turn the rotating beacon on or off. 6. ROLL-OVER PROTECTION SWITCH (Optional) This switch is used to engage or disengage the roll-over protection device. When the operator is about to start working with the backhoe attachment in conditions which could cause the machine to roll over, he/she must activate the roll-over protection device by pressing the switch (ON position and lamp turned on). In this condition, the audible alarm will sound by means of the buzzer when the pressure switch, installed on the backhoe attachment boom cylinder, detects a pressure exceeding the following values: 2WS = 116 bar (17 psi) 4WS = 126.5 bar (18 psi) 7. “GLIDE RIDE” SWITCH (Optional) The “glide ride” system control improves the machine comfort during travel, regardless of the type of terrain and with the loader bucket full or empty. It reduces forward and rearward pitching when moving rearwards or forwards and when carrying loads, at the same time increasing productivity and operator comfort. It also reduces impact forces to the machine during operation. Do not use this system while operating the loader attachment.

WARNING Never operate the “glide ride” system control when the loader arm and loader bucket are maintaining the front of the machine raised off the ground. The machine could fall and cause serious or fatal injury.

95

8. MANUAL MODE SELECTION SWITCH (Powershift transmission) In situations where manual gearshifting (up or downshift) is required, the automatic gearshift of the powershift transmission can be overridden by means of this switch. NOTE: changing gears up or down must always be done using the powershift transmission lever. When the manual mode is no longer required, place the switch back to the OFF position to return to automatic gearshifting. 9. HORN BUTTON This button operates the warning horn. 10. HAZARD LIGHT SWITCH Press the control down to locked position. The direction indicators and the control will flash simultaneously. Press the control down again to turn off the direction indicators and the lamp.

Copyright © 96


CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580T mechanical engine)

1. FRONT WORK LIGHT SWITCH This switch has three positions: - The first position is OFF (control lamp off).

3. SIDE WORK LIGHT SWITCH (Optional) This switch has two positions: - The first position is OFF (control lamp off).

- Second position, by pressing the symbol side (first click), the outer front work lights are turned on (control lamp on).

- Second position, by pressing the symbol side, the side work lights turn on at the same time (control lamp on).

- Third position, by pressing the symbol side again (second click), the inner front work lights are turned on too (control lamp on).

4. BACKHOE ATTACHMENT LOCKING SWITCH The switch is used to lock or unlock the backhoe attachment safety hook in preparation for road travel.

2. LIGHT SWITCH This switch has three positions: - The first position is OFF (control lamp off). - Second position, by pressing the symbol side (first click) the instrument cluster panel is powered, the side lights and the low beam indicator lamp are turned on (control lamp on). - Third position, by pressing the symbol side again (second click), the high beams are enabled and the low beams and the high beam indicator lamp are turned on (control lamp on).

5. REAR WORK LIGHT SWITCH This switch has three positions: - The first position is OFF (control lamp off). - Second position, by pressing the symbol side (first click), the outer rear work lights are turned on (control lamp on). - Third position, by pressing the symbol side again (second click), the inner rear work lights are turned on too (control lamp on). 6. SIDE INSTRUMENT CLUSTER

Copyright © SECTION 55 - ELECTRIC SYSTEM 7. BACKHOE ATTACHMENT QUICK COUPLER SWITCH (Optional) You have to press both switches to activate the quick coupler of the backhoe attachment. Press

on the 2 switches to unlock (retract

pins) of quick coupler on backhoe attachment. Press

on the 2 switches to lock (extend

pins) of quick coupler on backhoe attachment. 8. REAR WINDSHIELD WIPER AND WASHER SWITCH This switch has three positions: - The first position is OFF (lamp off) and both the windshield wiper and the windshield washer are disabled. - The second position allows to press the symbol side of the switch to activate the rear windshield wiper (lamp on). - The third position, allows to press the symbol side of the switch and hold to activate the windshield washer (lamp on). When releasing the switch, the windshield washer stops and the windshield wiper starts moving. 9. BACKHOE ATTACHMENT SIDESHIFT CARRIAGE HYDRAULIC SHIFTING SWITCH This button allows hydraulically moving the backhoe attachment towards the track sides. Press the button on the upper side of the symbol

to shift the backhoe attachment to the

right side of the track. Press the button on the lower side of the symbol


left side of the track (track sides are referred to the travel direction of the machine).

97

10. HORN BUTTON (only models with mechanical backhoe controls) This button operates the warning horn. 11. BACKHOE ATTACHMENT SIDESHIFT CARRIAGE LOCKING SWITCH (Sideshift version) It allows locking (control lamp on) or unlocking (control lamp off) the sliding carriage the backhoe attachment is mounted on.

Copyright © 98


CONTROL PANEL AND SIDE INSTRUMENT CLUSTER (580ST - 590ST - 695ST electronic engine)

1. FRONT WORK LIGHT SWITCH This switch has three positions: - The first position is OFF (control lamp off).

3. SIDE WORK LIGHT SWITCH (Optional) This switch has two positions: - The first position is OFF (control lamp off).

- Second position, by pressing the symbol side (first click), the outer front work lights are turned on (control lamp on).

- Second position, by pressing the symbol side, the side work lights turn on at the same time (control lamp on).

- Third position, by pressing the symbol side again (second click), the inner front work lights are turned on too (control lamp on).

4. BACKHOE ATTACHMENT LOCKING SWITCH The switch is used to lock or unlock the backhoe attachment safety hook in preparation for road travel.

2. LIGHT SWITCH This switch has three positions: - The first position is OFF (control lamp off). - Second position, by pressing the symbol side (first click) the instrument cluster panel is powered, the side lights and the low beam indicator lamp are turned on (control lamp on). - Third position, by pressing the symbol side again (second click), the high beams are enabled and the low beams and the high beam indicator lamp are turned on (control lamp on).

5. REAR WORK LIGHT SWITCH This switch has three positions: - The first position is OFF (control lamp off). - Second position, by pressing the symbol side (first click), the outer rear work lights are turned on (control lamp on). - Third position, by pressing the symbol side again (second click), the inner rear work lights are turned on too (control lamp on). 6. SIDE INSTRUMENT CLUSTER

Copyright © SECTION 55 - ELECTRIC SYSTEM 7. MENU SCROLLING SWITCH By means of this control, it is possible to scroll through the menu or data options shown on the diagnostic display. 8. MENU ENTER SWITCH By means of this control it is possible to display and confirm the menu options shown on the display. 9. REAR WINDSHIELD WIPER AND WASHER SWITCH This switch has three positions: - The first position is OFF (lamp off) and both the windshield wiper and the windshield washer are disabled. - The second position allows to press the symbol side of the switch to activate the rear windshield wiper (lamp on). - The third position, allows to press the symbol side of the switch and hold to activate the windshield washer (lamp on). When releasing the switch, the windshield washer stops and the windshield wiper starts moving. 10. BACKHOE ATTACHMENT SIDESHIFT CARRIAGE HYDRAULIC SHIFTING SWITCH This button allows hydraulically moving the backhoe attachment towards the track sides. Press the button on the upper side of the symbol


right side of the track. Press the button on the lower side of the symbol


left side of the track (track sides are referred to the travel direction of the machine). 11. HORN BUTTON (only models with mechanical backhoe controls) This button operates the warning horn. 12. BACKHOE ATTACHMENT QUICK COUPLER SWITCH (Optional) You have to press both switches to activate the quick coupler of the backhoe attachment. Press

on the 2 switches to unlock (retract

pins) of quick coupler on backhoe attachment. Press

on the 2 switches to lock (extend

pins) of quick coupler on backhoe attachment.

99

13. BACKHOE ATTACHMENT SIDESHIFT CARRIAGE LOCKING SWITCH (Sideshift version) It allows locking (control lamp on) or unlocking (control lamp off) the sliding carriage the backhoe attachment is mounted on.

Copyright © 100


SIDE INSTRUMENT CLUSTER (580T)

1. SIDE LIGHT AND LOW BEAM INDICATOR LAMP This indicator lamp turns on when the side lights or the low beams are on.

8. PARKING BRAKE INDICATOR LAMP This indicator lamp turns on when the parking brake lever is in the raised position (wheels braked).

2. MAIN BEAMS INDICATOR LAMP This indicator lamp turns on when the main beams are on.

9. AIR FILTER RESTRICTION LAMP This warning lamp turns on when the air filter element needs to be cleaned or replaced.

3. DIRECTION INDICATOR LAMP This lamp turns on when the direction indicators are working.

10. BATTERY CHARGE INDICATOR This indicator shows the state of charge of the battery. At normal charge the needle should be in the grey area. If the needle is in the left red area, this shows that the battery charge is insufficient or that the alternator is not charging the battery. If the needle is in the right red area, this indicates excessive battery charge which may cause damage to the battery.

4. AIR CONDITIONER INDICATOR LAMP (Optional) This lamp turns on when the air conditioner is working. 5. ENGINE OIL PRESSURE WARNING LAMP This warning lamp turns on and the audible warning device sounds when the engine oil pressure is too low. 6. “GRID HEATER” LAMP (Optional) If the machine is equipped with a “grid heater”, wait for the indicator lamp to turn off before starting the engine. 7. BATTERY CHARGE WARNING LAMP This warning lamp turns on when the alternator/ fan belt is broken or when the alternator is not charging the battery.

11. LOW FUEL LEVEL WARNING LAMP This warning lamp turns on when the fuel level is low. You have approximately an hour to fill the fuel tank. NOTE: when the starter switch key is in the ON position, lamps (5), (7), (8), and (9) turn on for three seconds. After this time, only lamps (7) and (8) remain alight.

Copyright © SECTION 55 - ELECTRIC SYSTEM 12. FUEL LEVEL GAUGE This gauge shows the quantity of fuel in the fuel tank. 13. HOURMETER The hourmeter shows the number of hours and tenths of hours the engine has been functioning. It also makes it possible to determine the intervals of the servicing operations. 14. TACHOMETER The tachometer shows the engine speed in revolutions per minute. The figures indicated must be multiplied by 100. Each intermediate mark shows a value of 100/ rpm. We recommend not to reach the red line. The tachometer shows travel speed in kilometres per hour (km/h) and miles per hour (mph). Road speed in 4th gear with 18.4-26 tyres. 15. TRANSMISSION OIL TEMPERATURE WARNING LAMP This indicator shows the transmission oil temperature. When the temperature is normal, the needle is in the grey area. If the needle is in the red area, change down to a lower gear. If the needle still remains in the red area, stop the machine travel, place the gearshift lever and the direction-of-travel control lever in the neutral position and leave the engine running at 1000/rpm. If this operation does not enable the oil temperature to be reduced, check the gearbox oil level and make sure that the radiator and oil cooler are perfectly clean. 16. ENGINE COOLANT TEMPERATURE GAUGE This indicator shows the temperature of the engine coolant solution. When the temperature is normal, the needle is in the grey area. If the needle is in the red area, the audible warning sounds.

101

Copyright © 102


SIDE INSTRUMENT CLUSTER (580ST - 590ST - 695ST)

1 1. CAUTION MASTER LAMP This lamp signals a not critical caution. When this caution is active, it is necessary to change the operating mode, plan a down time to carry out maintenance or, if the fault continues, consult your dealer. This warning lamp turns on at the same time of lamps (8), (10), (12) and (14) that indicates a fault on the machine. 2. SIDE LIGHT AND LOW BEAM INDICATOR LAMP This indicator lamp turns on when the side lights or the low beams are on. 3. MAIN BEAMS INDICATOR LAMP This indicator lamp turns on when the main beams are on. 4. DIRECTION INDICATOR LAMP This lamp turns on when the direction indicators are working. 5. “4 WHEEL STEER” (4WS) INDICATOR LAMP This lamp turns on when 4 wheel steer mode is selected and phased. 6. “ROAD” (4WS) STEER INDICATOR LAMP This lamp turns on when 2 wheel steer mode is selected and phased.

7. “CRAB” (4WS) STEER INDICATOR LAMP This lamp turns on when crab steer mode is selected and phased. NOTE: if the three lamps turn on at once, this means there is a problem with the electric circuit. Consult your Dealer. 8. ENGINE OIL PRESSURE WARNING LAMP This warning lamp turns on and the audible warning device sounds when the engine oil pressure is too low. 9. STOP MASTER LAMP The stop master lamp signals a critical caution. When this lamp turns on, stop the machine immediately and shut off the engine. If this is not the case, the machine can get damaged or accidents may occur. 10. BATTERY CHARGE WARNING LAMP This warning lamp turns on when the alternator/ fan belt is broken or when the alternator is not charging the battery. 11. PARKING BRAKE INDICATOR LAMP This indicator lamp turns on when the parking brake lever is in the raised position (wheels braked).

Copyright © SECTION 55 - ELECTRIC SYSTEM 12. AIR FILTER RESTRICTION LAMP This warning lamp turns on when the air filter element needs to be cleaned or replaced. 13. AIR CONDITIONER INDICATOR LAMP (Optional) This lamp turns on when the air conditioner is working. 14. “GRID HEATER” LAMP (Optional) If the machine is equipped with a “grid heater”, wait for the indicator lamp to turn off before starting the engine. 15. LOW FUEL LEVEL WARNING LAMP This warning lamp turns on when the fuel level is low. You have approximately an hour to fill the fuel tank. NOTE: when the starter switch key is in the ON position, all lamps turn on and the instrument buzzer sounds for 5 seconds. After this period only lamp (8) remains alight. The gauges (16) and (17) set to position. 16. FUEL LEVEL GAUGE This gauge shows the quantity of fuel in the fuel tank. 17. BATTERY CHARGE INDICATOR This indicator shows the state of charge of the battery. At normal charge the needle should be in the grey area. If the needle is in the left red area, this shows that the battery charge is insufficient or that the alternator is not charging the battery. If the needle is in the right red area, this indicates excessive battery charge which may cause damage to the battery. 18. DIAGNOSTIC DISPLAY By means of this display it is possible to visualize the various data of diagnostics. The service hours are also indicated. 19. TACHOMETER The tachometer shows the engine speed in revolutions per minute. The figures indicated must be multiplied by 100. Each intermediate mark shows a value of 100 rpm. We recommend not to reach the red line.

103

20. TRANSMISSION OIL TEMPERATURE WARNING LAMP This indicator shows the transmission oil temperature. When the temperature is normal, the needle is in the grey area. If the needle is in the red area, change down to a lower gear. If the needle still remains in the red area, stop the machine travel, place the gearshift lever and the direction-of-travel control lever in the neutral position and leave the engine running at 1000/rpm. If this operation does not enable the oil temperature to be reduced, check the gearbox oil level and make sure that the radiator and oil cooler are perfectly clean. 21. ENGINE COOLANT TEMPERATURE GAUGE This indicator shows the temperature of the engine coolant solution. When the temperature is normal, the needle is in the grey area. If the needle is in the red area, the audible warning sounds.

Copyright © 104


ANTI-START SYSTEM

A. B. C. D.

M38 Immobiliser Electronic key socket with LED 2 piece electronic key + 50 to ignition

WIRE No.

FUNCTION

E. Starter motor F. + 15 key positive G. Electronic key

CONNECTION

1

(+15) Key positive

Connected to the + 12 V full ignition supply

2

(+30) Permanent + 12 V power supply

Connected to the wire from the battery positive

3

(-31) Negative power supply

Connected to the vehicle negative at two independent points

5-6

Immobilization relay No. 2

Connected in line with the wire controlling the starter motor relay/solenoid - Minimum 500 mA maximum 10 A capacity

7-8-9

Immobilization relay No. 1

Connected in line with the cable controlling the ignition or the fuel system - minimum capacity 500 mA, maximum capacity 10 A


DIAGNOSTIC DISPLAY (580ST - 590ST - 695ST) The diagnostic display (1) is located in the middle of the side instrument cluster (4). The diagnostic switches are the following:

- MENU SCROLL SWITCH (2) Use this UP/DOWN switch to scroll through the menus. NOTE: push the arrow at start up to display engine rpm on the display.

- DISPLAY ENTER SWITCH (3) Use this switch to select and confirm a service menu. The Diamond icon, or top portion of the switch, is used to select displays. The 90° arrow icon or bottom portion of the switch, is used to enter selected choices.

105

Copyright © 106


Using the display switches, you will be able to scroll through the following: - battery voltage; - backhoe loader hours; - setup.

Features adjustable during setup: - backlighting dimming and contrast control, - maintenance/service interval customization; - storage of error codes; - “grid heater” presence: it is possible to select or deselect the “grid heater” option; - low temperature idle speed setting: when the engine coolant temperature is below 10 °C (50 °F), the unit will change from a normal low idle to a low temperature idle which can be adjusted between 975 and 1500 rpm. The default setting is 1000 rpm; - high idle speed setting (2500 rpm maximum).


107

SYMBOLS Work hours

Maintenance

Maintenance heavy (hours)

Maintenance light (hours)

Stored error code

Grid heater

Engine speed

Engine area of fault

Engine intake air filter blocked

Charge air temperature too high

Engine coolant level too low

Engine coolant temperature too high

Engine oil pressure too low

Brake fluid level too low

Parking brake engaged

Put the shuttle lever into neutral position

Hydraulic oil filter blocked

Transmission oil pressure too high

Battery charging failure

Contaminated fuel

Malfunction

Back-light dimming

Battery voltage too high

Battery voltage too low

Copyright © 108


SETUP MENU

Dimmer Increase Decrease

Increase Decrease Service interval

Increase Decrease Stored error code

3-second scroll unless the switch is pressed “Grid heater” presence

Select / Deselect

Low and high idle speed

Increase Decrease

Hardware code

Software code

HARDWARE P/N ID VER

SOFTWARE P/N ID VER

Increase Decrease

Press Enter to make the value flash and then set up Press Enter to make the value stop flashing


109

PROCEDURE ABOUT SELF TEST

Any of the above at with ignition low

Power up LCD and show work hours for 10 seconds

Go to menu Normal “Key ON”

Maximum foot accelerator: X.X. Minimum foot accelerator: 113/111 field X.X.

Maximum accelerator knob: X.X. Minimum accelerator knob: X.X.

125/120 field

Initiate Self test Accelerator pedal %: XXX 113/122 Accelerator knob %: XXX field

Any of the keys above and with “Key ON”

Step 1: Lamps switch on at full intensity.

Check: 100 mA < Current draw < 1amp

Step 2: Lamps switch off after 2 seconds.

Requested engine rpm: XXX

98/88 field

Fuel level: XX.X Fuel tank: XX

117/120 field

Voltage: XX.X Transmission oil temperature: XX

116/124 field

Brakes: XXX Engine rpm: XXXX

102/92 field

Radiator water temperature XXX Air temperature XXX

107/123 field

Engine oil temperature: XXX Fuel temperature: XXX

122/126 field

10 mA < Current draw < 1 mA Step 3: Wait 2 seconds.

Step 4: Instrument backlighting turns on at full intensity.

Step 5: Lamps switch off after 2 seconds.

Check: 100 mA < Current draw < 1 A

10 mA < Current draw < 100 mA

Step 6: Wait 2 seconds.

Step 7: Sweep all 5 gauges to maximum angle.

Step 8: 2 seconds after maximum angle sweep to red border.

Step 9: 2 seconds after red-green border is reached move to second red border for voltage.

Makes sure that needles can move freely and have proper position

Makes sure that needles are properly calibrated to applique

Step 10: Park all gauges and start LCD test.

Step 11: When LCD test is complete sound alarm for 2 seconds.

Step 12: The following is shown on the LCD display until the key is turned to OFF or the cycle ends. All gauges and lamps should work as normal and engine will be able to be started.

Copyright © 110


ON BOARD ERROR CODE RETRIEVAL

Stored error code

Page 1/6 CODE

3059

OCCURRENCE 3 TIME

1004.5

Page 2/6 CODE

3009

OCCURRENCE 2 TIME

1010.6

Page 3/6 CODE Occurrence counter will be incremented on transition from inactive to active status. Status has to be stored in EEPROM and checked at key on. Only the hour count of the last occurrence will be stored per SAE convention.

1018

OCCURRENCE 1 TIME

1024.5

Page 4/6 CODE

3022

OCCURRENCE 1 HOUR 969

.4

Page 5/6 CODE

3113

OCCURRENCE 2 TIME

1050.6

Page 6/6 CODE

1003

OCCURRENCE 3 TIME

1076.4

3-second scroll unless the up/down button is pressed


111

BACKLIGHTING AND DIMMING A proper and uniform backlighting for matrix, gauge pointer and symbols shall be provided. Separate backlighting electronics shall be provided for matrix and symbols-gauge pointers. The backlighting will be achieved by LEDs and dimming shall be provided through the setup menu selections. The backlighting shall go at its maximum level when the front, rear and driving lights are off. The gauges backlighting dimming is switched on when the cluster sees a HIGH level on front work lights, rear work lights or driving lights for more then 100 ms. The lamps intensity is decreased when side lights are activated. The two different brightness levels are defined as 100% during daytime use and 50% when backlighting is active. The display intensity of luminance will be 6 cd/m2 (not dimmed). The maximum available luminance spread will be 30%. To avoid dark zones the maximum difference of intensity of luminance between closed points is 15%.

DIMMING LAW The dimming adjustment is done through the setup menu, it can be used in single. In single step mode, the luminance level go from min to max value in 10 steps. The luminance levels of display and gauges always varies in parallel. The cluster switches between day and night luminance levels using the work and driving light status, and is able to manage the display and gauges independently using the same law and customer setting. Only the night settings can be adjusted since the day setting of the display is 100% intensity. During dimming setup the matrix shows the dimming symbol together with the percentage of luminance: its value varies using a step of 10%. The dimming symbol appears when the proper menu is selected and stays on the matrix for at least 2 seconds. The dot matrix visualization will be as follows:

Note that the matrix backlighting may go to 0 by customer selection. The lamps and the audible alarm will warn the customer of an alarm condition occurring.

The default value is 80% and the may go to zero if set by the customer.

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WORK HOURS In order to allow service or the customer to view vehicle hours of operation, it will not be necessary to have the key. By pressing the menu enter/display scroll switch, with the key turned to OFF, the instrument cluster panel will activate and display the service hours for 10 seconds. The hourmeter increments when the engine is running (rpm> 600). The hours are displayed starting from 0.0 until 210,554,060.7 using an interval of 6 minutes. In case of battery disconnection, the cluster can lose 0.1 hour or 6 minutes max.

- once in the adjustment mode the meaning of the arrow UP switch is “increase hourmeter value”, and the meaning of arrow DOWN switch is “decrease hourmeter value”. A single pressure of the switch will increase or decrease the value by one unit (6 min). Continuous switch pressure will increase or decrease the value continuously (1 every 300 milliseconds): when the value reaches a multiple of 10, the increment/decrement rate is 10 units every 300 ms; when the value reaches a multiple of 100, the rate is 100 units every 300 ms; when the value reaches a multiple of 1000, the rate is 1000 units every 300 ms. During continuous setting the value stops flashing.

WORK HOURS SETTING In order to allow service to install a new Vehicle Control Module (VCM) on an old vehicle, it is possible to increase (no decrease will be allowed) the hour to the same setting as the original. To modify the hourmeter value, execute the following procedure:

Once the operator has reached the desired value press and hold down the arrow UP and display switches for 15 seconds to end setting procedure. It is not possible to set a value lower than the current one, and the procedure can be repeated three times in the cluster life.

- select the hourmeter function on the display; - press and hold depressed for 15 seconds “arrow UP” and “display” until the value shown on display starts to blink (1 Hz, duty 50%);

Work hours

Any of the above at with ignition low

Power up LCD and show work hours for 10 seconds

To save the new value Hourmeter setting

With the key turned to ON, press for 15 seconds Blinking to indicate ability to edit values

0.1, 1, 10, 100 or 1000 hours step depending on continuous time pressed To exit without saving

Value may only increase for the hourmeter. While setting the value it can be decreased due to operator overshoot, but the value can not be stored if it is below the current stored value. Pressing DISPLAY will exit without saving. ENTER must be pressed to store the modified value in protected memory.


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OPERATION Auto wake up at every 600 ms for sensing a change in ENTER, DISPLAY, UP or DOWN switch status will be provided. Upon sensing of one of those inputs transition, the cluster has to wake up.

With the key OFF, all indicators set to the parking position. The parking position is hard to obtain with the internal stops of the stepper motor. With the key ON, follow the procedure below.

As a general rule, at engine start-up, it is necessary to deactivate all alarms and instrument gauges, unless an error is detected on the starting line.

Needle collision control at key-on At key-on drive all needles CCW for 1 second

Vibration, service, transport or battery loss can generate a FALSE

If RTZ is observed on all 5 gauges

TRUE

FALSE Remove power from gauges: - engine coolant - fuel level

Drive gauges until they reach: - tachometer - transmission temp - battery voltage

Drive gauges: - engine coolant - fuel level Start all normal display functions

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TACHOMETER

ENGINE COOLANT TEMPERATURE INDICATOR

The tachometer accuracy should be less than or equal ±50 rpm.

A stepper motor will drive coolant temperature gauge. The gauge accuracy should be less than or equal 3%. Needle calibration has never to be lost for any external condition.

The above-specified tolerances must be respected in all operating ranges (temperature, voltage, etc.). A stepper motor will drive the tachometer. Needle calibration has never to be lost for any external condition. The message to be used is EEC1. EEC1 MESSAGE

INSTRUMENT POSITION

0000

0 rpm

0001 => FFFD

According to the value

Green field

0 ÷ 2500 rpm

Red field

2500 ÷ 3000 rpm

FFFF

0 rpm

In case of faulty sensor, the instrument will go back to parking position. Since this signal is a function of the engine controller the appropriate warning lamp and lamp will be illuminated. During cranking, the needle movement shall be frozen in order to inhibit any spurious movement of it.

INSTRUMENT

TEMPERATURE

Gauge indication range

+65 ÷ +112 °C (+149 ÷ +234 °F)

Green field

+65 ÷ +106 °C (+149 ÷ 223 °F)

Red field

+106 ÷ +112 °C (+223 ÷ 234 °F)

The message to be used is engine temperature. ENGINE TEMPERATURE MESSAGE

INSTRUMENT POSITION

00 => FD

According to the logic above

FE

Minimum value

FF

Minimum value

An audible alarm must sound when the engine temperature exceeds 106 °C (223 °F). In case the sender is disconnected, the gauge has to go to 65 °C (149 °F) position. Reconnecting the sensor the gauge has to return to the correct position. Both the movements have to be uniform. In case of faulty sensor, the instrument will go back to parking position. Since this signal is a function of the engine controller the appropriate warning lamp and lamp will be illuminated. During cranking, the needle movement shall be frozen in order to inhibit any spurious movement of it.


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VOLTMETER GAUGE

TRANSMISSION OIL TEMPERATURE GAUGE

The voltmeter will indicate the voltage of the vehicle electric system.

The oil temp gauge indicates transmission oil temperature from 75 °C ÷ 115 °C (167 ÷ 239 °F). This gauge is broken up into two ranges, green and red. The green field goes from 75 °C ÷ 106 °C (167 ÷ 223 °F). The red zone is from 105 °C ÷ 115.5 °C (221 ÷ 240 °F). This gauge will be connected to a sensor that will provide a specific resistance to correlate to a specific oil temperature.

This gauge will have three operating ranges: two reds and one green. One red range will indicate low voltage. The other red will indicate high voltage. The green range will indicate normal operating voltage. Bottom of the scale will be 9 V.

INSTRUMENT

TEMPERATURE

Low voltage range is 11 V or less.

Gauge indication range

The pointer will be at ±3° from the thick centerline that indicates 11 V.

+75 ÷ +115 °C (+167 to +239 °F)

Green field

+75 ÷ +106 °C (+167 ÷+ 223 °F)

Red field

+105 ÷ +115.5 °C (+221 ÷ +240 °F)

The normal operating range will be 11 V to 16 V. High voltage range is 16 V or higher. The pointer will be at ±3° from the thick centerline that indicates 16 V. Top of the scale will be 18 V. A stepper motor will drive the voltmeter gauge. The gauge accuracy should be less than or equal 3%. Needle calibration has never to be lost for any external condition. Loss of voltmeter sensor will be the loss of the internal VCM A/D converter. During cranking, the needle movement shall be frozen in order to inhibit any spurious movement of it. A/D accuracy is specified as ±180 mV during self test operation.

- 5 V = 75 °C (167 °F). The centerline of the pointer will be at ±2 angular degrees from the centerline of the bold reference mark that indicates this temperature. - 2.6 V = 93.3 °C (200 °F). The centerline of the pointer will be at ±3 angular degrees from the centerline of the bold reference mark that indicates this temperature. - 2.05 V = 115.5 °C (240 °F). The centerline of the pointer will be at ±2 angular degrees from the centerline of the bold reference mark that indicates this temperature. The same range of temperature is used for powershift and powershuttle transmissions. The gauge will move by 9 angular degrees at keyon in the clockwise position, to replicate the current instrument cluster behaviour. This is necessary due to the cool temperatures present when the unit is working in backhoe position. In case the sender is disconnected, the gauge has to go down to home position. Reconnecting the sensor will make the error code inactive and the gauge has to return to the correct position. Both the movements have to be uniform. A stepper motor will drive the transmission oil temperature gauge. The gauge accuracy should be less than or equal ±2%. Needle calibration has never to be lost for any external condition. During cranking, the needle movement shall be frozen in order to inhibit any spurious movement of it.

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FUEL LEVEL GAUGE When a certain low fuel level is reached, the relevant “low fuel” lamp will be lit according to the following logic. The filtering of the data read is obtained with a hysteresis on the resistance value joined to a delay time of 2 seconds. Ohmic parameter threshold and delay time value must be kept in NVM. Lamp activation depends on values used for needle movement; this means that at key-on the low fuel level warning is active if the cluster sees a resistance value greater the table below. Resistance values The fuel level gauge will indicate the fuel level of the vehicle tank. The gauge dial will be divided into two ranges: red and green. The red range will indicate a low fuel zone. The green range will indicate a non-low fuel zone. This gauge will be connected to a sensor that will provide specific a resistance to correlate to a specific fuel tank level. TANK SIZE 133 litres (29.25 gal)

EMPTY VALUE (X) 320 Ohm

RED-GREEN BORDER (Y) 186 Ohm

- X = empty. The centerline (CL) of the pointer will be at +0° / -2° angular degrees from the centerline of this empty mark. - Y = red - green threshold. The centerline (CL) of the pointer will be at +/-3 angular degrees from the centerline of this “half” mark. - Z = full. The centerline (CL) of the pointer will be at +4/-0 angular degrees from the centerline of this “full” mark.

FULL VALUE (Z) 6.5 Ohm

INDICATED FUEL LEVEL 30% with 18 angular degrees of gauge motion

In case the sender is disconnected, the gauge has to go down in empty position. Reconnecting the sensor the gauge has to return to the correct position. Both the movements have to be uniform. A stepper motor will drive fuel level gauge. The gauge accuracy should be less than or equal ±2%. Needle calibration has never to be lost for any external condition. During cranking, the needle movement shall be frozen in order to inhibit any spurious movement of it.


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WARNING SYSTEM The diagnostic has to inform the operator regarding all the operating conditions of the loader backhoe which are out of range. These conditions are different from each other: - warnings; - error codes;

ALARM ACTIVATION Non Critical A failure is present but the operator can continue his work: the purpose is to warn the operator as regards the presence of the fault. A beep will sound every 30 seconds.

- faults in the system;

Critical

- required action.

A serious fault that can affect either the safety of the operator or the damage of the loader backhoe is present: the operator shall stop the loader backhoe. This will be a continuous alarm.

We can define warnings as all those situations that could be dangerous for the loader backhoe or for the operator.

Action Required

The diagnostic will move the display to the red range or will activate the buzzer.

The system is asking for a certain manoeuvre from the operator in order to return to the normal functionality. This will be a continuous alarm.

The display will show the symbol indicating the current problem.

Safety

There are conditions in which the diagnostic detects one of its sensors out of order: in this case it will generate an error code. According to the severity of the failure, it will control the relevant warning lamp and the audible alarm: the display will display the appropriate Icon together with the error code number. If it is necessary to inform the operator that he/she has done an incorrect manoeuvre, or that he/she must perform a special operation (required action), the diagnostics will display an icon again or will activate the relevant buzzer.

The system purpose is to warn the operator regarding the presence of a dangerous situation for his safety. This will be a continuous alarm. General Sound There are certain conditions in which it is necessary to activate an audible alarm. It is a one-second beep to draw the operator’s attention to the instrument cluster.

Whenever an audible alarm activation is related to an icon visualization, this icon should remain displayed at least for 4 seconds in order to give the possibility to the operator to understand the cause of the alarm activation. When many warnings with different priority occur, the audible alarm is related to the higher priority warning. When a warning activates with an audible alarm different from the current one, the corresponding icon must be displayed simultaneously. If a warning lamp dedicated to a function is associated to the activation cause of the audible alarm, the warning lamp will activate together with the audible alarm.

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MAINTENANCE Two different kinds of maintenance will be available: - light maintenance; - heavy maintenance. LIGHT MAINTENANCE From 2 hours before the set value, display on the display the “light maintenance symbol” at every key on for 1 second after cranking; after this, the last selected icon will be visualized on the display. The hours shown will be the hours when light maintenance is required, not the standard hours displayed by the hourmeter.

HEAVY MAINTENANCE From 10 hours before the set value, display on the display the “heavy maintenance symbol” at every key on and should last for 1 second after cranking. After cranking after this, the last selected icon will be visualized on the display. The hours shown will be the hours when light maintenance is required, not the standard hours displayed by the hourmeter.

Amber-coloured lighting The interval can be set between 50 and 500 hours in steps of 100 (0.0, 500, 600, 700, 800, 900, 1000). The 0.0 setting turns the heavy maintenance feature off.

Amber-coloured lighting The interval can be set between 50 and 500 hours in steps of 50 (0.0, 50, 100, 150, 200, 250, 300, 350, 400, 450, 500). The 0.0 setting turns the light maintenance feature off.

DISPLAY FUNCTION When the hourmeter reaches the light service interval

3 seconds

3 seconds

GREEN AMBER Audible alarm for 1 second when displaying either service interval for the first time When the hourmeter reaches the heavy service interval

3 seconds

3 seconds GREEN

AMBER

Audible alarm for 1 second when displaying either service interval for the first time Since heavy maintenance contains light maintenance the following will be shown: 500 - Light 1000 - Heavy 1500 - Light 2000 - Heavy The service indicator message will be cleared with a single key cycle


119

WARNING MESSAGES Function

Engine coolant temperature too high Engine oil pressure too low

Lamp

Alarm

Continuous

Continuous

Lamp

Display lamp

Condition

DTC

SA

Description

Priority Colour

Coolant above Coolant 112 °C 1002 VCM temperature 1 (234 °F) for 5 signal - too high seconds Pressure <26 bar (377 psi) 500> rpm

Red

Oil pressure 3028 ECU sensor 1 pressure too low

Red

Red

Transmission oil pressure too low

Continuous

The engine must Switch closed be running with to ground for 1008 VCM 1 switch closed for 25 seconds 25 seconds

Malfunction

Continuous

5 seconds without message

1051 ECU

Time-out of message

1

Red

Malfunction

Continuous


1053 ECU

Time-out of message

1

Red

Malfunction

Continuous


Time-out of 1054 VCM message engine 1 temperature

Red

Malfunction

Continuous


Time-out of 1055 VCM message inlet/ exhaust

1

Red

Malfunction

Continuous


Time-out of 1056 VCM message engine 1 fluid

Red

Malfunction

Continuous


Time-out of 1057 VCM message electric system

1

Red

Malfunction

Continuous


1059 VCM

Time-out of 1 message display

Red

Transmission oil temperature too high

Continuous

Transmission oil above Transmission oil 115 °C 1009 VCM temperature limit 1 (239 °F) for 5 reached seconds

Red

General display message

Continuous

DTC’s 3000 3366

Only display with display request

1

Red

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Function


Lamp

Alarm

Lamp

Display lamp

Condition

One touch idle active

DTC

N/A

SA

Description

Priority Colour

VCM

1

Red

This prevents VCM damaging the parking brake

Continuous, if vehicle is in gear

Switch closed N/A to ground

2

Red

Brake temperature too high

Continuous

Sender temperature Warns customer over 152 °C 1006 VCM before brake 2 (306 °F) for 5 fade seconds

Red

Engine oil pressure too high

Continuous

Pressure depends on speed

2

Red

Battery charge voltage too high

Continuous

3051 ECU

Battery voltage too high

2

Red

Battery charge voltage too high

Continuous

Supply Supply battery source above 1014 VCM voltage above 16 V for 5 16 V seconds

2

Red

Battery charge voltage too low

Continuous

3052 ECU

Battery voltage too low

2

Red

Continuous

Supply Supply battery source below 1015 VCM voltage below 11 V for 5 11 V seconds

2

Red

Alternator unable to charge

Continuous

Alternator L+ terminal Alternator 1050 VCM 2 under 1.5 V unable to charge for 5 seconds

Red

Accelerator pedal signal out of range

One second alarm every 30 seconds

IVS not changing state in 300 ms

Foot accelerator 1010 VCM sensor - not 2 plausible

Amber



Accelerator Foot accelerator above 4.75 V 1011 VCM sensor -signal 2 for 5 seconds above range

Amber



Accelerator Foot accelerator under 0.25 V 1012 VCM sensor -signal 2 for 5 seconds below range

Amber

Parking brake engaged

Battery charge voltage too low

3032 ECU


Function

Lamp

Alarm

Lamp

Display lamp

Condition

DTC

SA

121

Description

Priority Colour



Foot accelerator 1013 VCM sensor - no 2 signal

Amber



Accelerator Foot accelerator above 9 V for 1029 VCM sensor - shorted 2 5 seconds high to Vbat

Amber



Accelerator Foot accelerator under 0.5 V 1030 VCM sensor - shorted 2 for 5 seconds low to Vbat

Amber

5V accelerator pedal power supply


Accelerator Foot accelerator above 5.1 V 1023 VCM supply voltage 2 for 5 seconds too high

Amber



Accelerator Foot accelerator under 4.9 V 1024 VCM supply voltage 2 for 5 seconds too low

Amber



Accelerator Foot accelerator above 9 V for 1025 VCM supply shorted 2 5 seconds high to Vbat

Amber



Foot accelerator Accelerator supply voltage under 0.5 V 1026 VCM 2 shorted low to for 5 seconds ground

Amber

Accelerator knob signal out of range


Accelerator Accelerator knob sensor above 4.75 V 1035 VCM signal above for 5 seconds range

2

Amber



Accelerator Accelerator knob sensor under 0.25 V 1036 VCM signal above for 5 seconds range

2

Amber



Accelerator 1037 VCM knob sensor - no 2 signal

Amber

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Function


Lamp

Alarm

Lamp

Display lamp

Condition

DTC

SA

Description

Priority Colour



Accelerator Accelerator knob sensor above 9 V for 1038 VCM shorted high to 5 seconds Vbat

2

Amber



Accelerator Accelerator knob sensor under 0.5 V 1039 VCM shorted low to for 5 seconds ground

2

Amber

5V accelerator knob power supply


Accelerator Accelerator above 5.1 V 1031 VCM knob supply 2 for 5 seconds voltage too high

Amber



Accelerator Accelerator under 4.9 V 1032 VCM knob supply for 5 seconds voltage too low

2

Amber



Accelerator Accelerator knob supply above 9 V for 1033 VCM voltage shorted 5 seconds high

2

Amber



Accelerator Accelerator knob supply under 0.5 V 1034 VCM voltage shorted for 5 seconds low

2

Amber

Continuous

Switch closed to ground with vehicle in N/A gear and no parking brake

This must have a debounce VCM 2 time of less then 500 ms

Amber

Seat not in driving position

Boost temperature over

Boost air temperature too high




Coolant Engine over above 106 °C operating 1019 VCM (223 °F) for 5 coolant seconds temperature



Coolant 3007 ECU temperature signal high

88 °C (1276 °F) for 5 seconds

Engine over 1018 VCM operating boost air temperature

3

Amber

Amber

3

Amber


Function

Lamp

Alarm

Transmission oil temperature above 105 °C


Fuel temperature too high



Lamp

Display lamp

Condition

DTC

SA

123

Description

Coolant above Transmission 105 °C 1020 VCM over operating (221 °F) for 5 temperature seconds

Priority Colour

3

Amber

Fuel over 1021 VCM operating temperature

3

Amber


Fuel temperature 3015 ECU signal source high

3

Amber



Fuel 3016 ECU temperature signal no signal

3

Amber

Clogged air filter


Switch closed Air filter to ground for 1001 VCM threshold 5 seconds

4

Red

Air conditioning not functional


Switch closed Air conditioning to Vbat for 5 1003 VCM 4 system pressure seconds

Amber

Hydraulic oil filter restriction


Switch closed Hydraulic filter to ground for 1004 VCM threshold 5 seconds

4

Red

Fuel contaminated with water


Display message

1022 VCM

4

Amber

Fuel level sensor


Fuel sender Fuel sender shorted high above 9 V for 1043 VCM instrument in 5 seconds stand-by

4

Amber

Fuel level sensor


Fuel sender Fuel sender shorted low below 0.5 V 1044 VCM instrument in for 5 seconds stand-by

4

Amber

Fuel level sensor


Input is switched battery for 5 seconds

4

Amber

Fuel over 82 °C (1189 °F) for 5 seconds

Fuel sender open circuit 1045 VCM instrument in stand-by

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Function


Lamp

Alarm

Lamp

Display lamp

Condition

DTC

SA

Description

Priority Colour



Transmission Transmission temperature temperature sender above 1046 VCM sender shorted 9 V for 5 high seconds

4

Amber



Transmission Transmission temperature temperature sender below 1047 VCM sender shorted 0.5 V for 5 low seconds

4

Amber



Input is switched battery for 5 seconds

Transmission 1048 VCM temperature open circuit

4

Amber

Brake temperature sensor


Brake Sender over temperature 1000 Ohm for 1049 VCM sender out of 5 seconds range

4

Amber

General display message

One-second alarm

DTC’s 3000 3366

Only display VCM with display request

4

Amber

Low fuel warning

One-second alarm

Low fuel - must stay on for VCM remaining key cycle

5

Amber


125

STARTING SYSTEM OPERATION

CHECKING THE STARTER MOTOR SYSTEM

The system includes a key switch, a reinforced wiring, a starter motor and a relay-solenoid valve assembly.

To troubleshoot the starter motor system rapidly and easily, it is recommended that a battery-starter motor testing device (quick discharge) be used, which includes a 0 - 20 V voltmeter and a 0 - 500 A ammeter to detect problems in the starter motor system.

The starter motor has a built-in solenoid valve and a positive engagement drive system. When the key switch is operated with the forward and reverse travel lever in neutral position, the solenoid coils are energized and cause the piston to be magnetically drawn inside the solenoid. This movement causes the drive pinion to mesh with the ring gear on the engine flywheel. When the pinion touches the ring gear, the piston of the solenoid valve closes a series of contacts enabling the battery to directly power all four field coils, thus providing full power to the starter motor. The starter motor contains a single set of contacts and a solenoid valve piston, which completely closes the contacts, even if the teeth of the pinion are not perfectly aligned with the teeth of the ring gear. In this case, a spring is compressed and forces the complete engagement of the pinion as soon as the starter motor starts rotating. Once the ignition is turned off, the solenoid and the starter motor are de-energized. The solenoid’s recoil spring causes the drive pinion to be uncoupled and the contacts of the solenoid to reopen.

Use a testing device in accordance with the manufacturer’s instructions. If a testing device of the type indicated is not available, use a standard 0 - 20 V voltmeter and a 0 - 500 A ammeter to check the operation of the starter motor on the vehicle. Before testing: - check that the battery is fully charged. - check that no wire of the starting system is cut or stripped and that the connections are not loose. - check that the motor is not seized.

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Current draw on the starter motor system Disconnect the ground cable (negative) from the battery (3). Disconnect the positive cable from the battery on the solenoid of the starter motor. Connect the positive cable of the ammeter (1) to the positive terminal of the battery and the negative cable to the input terminal of the solenoid. Reconnect the ground cable (negative) of the battery to the negative terminal of the battery. Connect the positive cable of the voltmeter (2) to the positive terminal of the battery and the negative cable of the voltmeter to the negative terminal of the battery. Disconnect the injection pump fuel inlet cut-off wire from the solenoid. Start the motor and observe the values indicated by the voltmeter and ammeter. The voltage must remain steady at around 12 V with a current draw of 250 - 300 A. If the current draw is within the indicated range, the starter motor (4) is operating correctly. If the voltage drops during the test, refer to chapter “Resistance on the system of the starter motor system”. If the current draw is higher than the specified range, check the system as indicated below. If tests of the starting system have proved satisfactory, the starter motor is defective and must be removed in order to identify the source of the problem. If the current draw is less than the specified range, the starter motor is defective and must be removed in order to identify the source of the problem.

Copyright © SECTION 55 - ELECTRIC SYSTEM RESISTANCE ON THE SYSTEM OF THE STARTER MOTOR (Voltage lowering) If the current draw is excessive, it is necessary to check the system according to the voltage drop occurring between its single components. IMPORTANT: disconnect the injection pump fuel inlet cut-off wire from the solenoid. Positive cable of the battery Connect the positive cable of the voltmeter (1) to the positive terminal of the battery (2). Connect the negative cable of the voltmeter (1) to the battery terminal of the starter motor solenoid valve (3). Start the starter motor and observe the reading on the voltmeter. If the voltage drop exceeds 0.2 V, check and retighten the cable connections. Check the voltage again. If it is still excessive, replace the cable.

Starter motor connections to ground Connect the positive cable of the voltmeter (1) to the body of the starter motor (2). Connect the negative cable of the voltmeter (1) to the motor block (3). Start the starter motor and observe the reading on the voltmeter. If the voltage drop exceeds 0.2 V, check and retighten the cable connections, check the ground connections between the starter motor clamp and the undercarriage.

Ground cable of the battery Connect the positive cable of the voltmeter (1) to the motor block (2). Connect the negative cable of the voltmeter (1) to the negative terminal of the battery (3). Start the starter motor and observe the reading on the voltmeter. If the voltage drop exceeds 0.2 V, check and retighten the ground cable connections. Check the voltage again. If it is still excessive, replace the ground cable.

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STARTER MOTOR TECHNICAL SPECIFICATIONS Manufacturer .............................................................................................................................................Denso Voltage .........................................................................................................................................................12 V Rated power............................................................................................................................................. 2.7 kW Starting system .......................................................................................................................................Positive Operating time.............................................................................................................................................. 30 s Direction of rotation .................................................................................... Clockwise seen from the pinion side Weight ......................................................................................................................................... 8.4 kg (18.5 lb) Maximum consumption without load at 11 V and 3000 rpm minimum ...................................... 200 A maximum Maximum consumption with a torque of 19.6 Nm (14.5 lbf·ft) at 8 V and 1130 rpm minimum .........600 A maximum Maximum consumption when shimming at 3 V with a torque of 39.2 Nm (568 lbf·ft) minimum ......1400 A maximum

MAIN COMPONENTS 1. Motor 2. Induction coils 3. Armature 4. Commutator 5. Brush assembly 6. Pinion gear 7. Intermediate pinion 8. Solenoid 9. Clutch 10. Drive pinion


129

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1. Shim 2. Bearing 3. Armature 4. Bearing 5. Coils housing 6. Protection 7. Brush spring 8. Brush assembly 9. Disc 10. Cover 11. Screw 12. Screw 13. Drain 14. Screw 15. Protection 16. Gasket 17. Washer 18. Nut 19. Rod 20. Connection assembly 21. Screw 22. Connection assembly 23. Nut 24. Ring 25. Roller 26. Cage 27. Pinion 28. Ball 29. Spring 30. Drain 31. Screw 32. Washer 33. O-ring 34. Flange 35. Pinion, rings and spring assembly 36. O-ring 37. Bearing 38. Bearing 39. Spring 40. Shaft 41. Body 42. Clutch assembly

Copyright © SECTION 55 - ELECTRIC SYSTEM REMOVAL AND INSTALLATION Disconnect the ground cable (negative) from the battery. Remove the rear protection cover and disconnect all cables connected to the starter motor. Remove the three retaining screws of the starter motor and remove the starter motor. To install the starter motor again, proceed in the reverse order to that of removal.

TEST BENCH CHECK Check NOTE: before carrying out the test, check that the battery is fully charged then obtain a battery-starter motor testing device (quick discharge) and a carbon cell (variable load resistance). Lock the starter motor in a vice with soft jaws. Connect the negative cable (4) of the battery to the mounting flange of the starter motor. Connect a short cable (6) between the solenoid battery wire and the terminals of the solenoid switch. Connect the positive cable of the voltmeter (3) to the positive terminal of the battery and the negative cable to the negative terminal of the battery, the positive cable of the ammeter (1) to the positive terminal of the battery and the negative terminal the solenoid valve battery or to the starter motor clamp. Install a tachometer (5) at the end of the armature shaft. Activate the starter motor by adjusting the carbon cell (2) to obtain a voltage of 11 V. When the armature is rotating at 3000 rpm, the maximum current draw must not exceed 200 A. If the starter motor does not operate in these conditions, check that the field coils are not grounded, that the armature is not rubbing and that its shaft is not deformed.

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Armature The surface of the commutator must be clean and without traces of burns. If necessary, remove traces of burns using fine sandpaper. Do not use emery cloth. Then, clean the commutator with a cloth soaked in gasoline. After rectifying the commutator, polish it with fine sandpaper, then wipe it with a cloth soaked in gasoline. NOTE: make sure not to graze the metal of the commutator during rectification of insulating notches. The resistance of the armature insulation may be checked by connecting an ohmmeter (1) between the blades of the commutator (2) and the armature shaft (3). The resistance must be infinite (no continuity). To check that the armature is not short-circuited, a special device for armatures must be used. The other solution is to replace the armature. If the circumference of the armature has come into contact with the starter pole shoes, the bearings of the armature are probably excessively worn out. First check that the starter pole shoes have been tightened and that the armature rotates without any concentric defect. If necessary, replace the armature bearings. Field coils To check the resistance of the field coil insulation, connect an ohmmeter (1) between the brushes of each induction coil (2) and a clean unpainted area of the body (3). The resistance must be infinite (no continuity). To check the continuity of the field coils, connect an ohmmeter between the brushes of each induction coil and the main supply terminal (the thickest braided wire). The resistance must be equal to 1 MW. If the field coils are defective, the entire assembly consisting of the body and the field coils must be replaced. Drive pinion The drive pinion must only rotate clockwise. If the pinion is seized or turns in both directions or if its teeth are damaged, change the complete drive assembly. NOTE: if the teeth of the drive pinion are damaged, also check the teeth of the engine flywheel ring gear.


133

TROUBLESHOOTING STARTING SYSTEM The motor does not start when the starter switch key is operated and the transmission is in the neutral position. Is the battery properly charged?

NO

Charge or replace the battery.

YES Check the starter motor wiring. Are there bad connections, cut or stripped cables?

Repair or replace the cables.

YES

NO Is the starter motor seized?

YES

Repair or replace the starter motor.

NO Operate the starter switch key. Is there a voltage of +12 V on the (white) input wire of the starting solenoid valve (terminal 30)?

YES

Does the solenoid make a “clicking” sound?

YES

Windings, brush or starter motor mechanism possibly defective.

NO

NO Check the starter motor relay (K01). Can you hear the relay operate after operating the starter switch key? NO

Solenoid possibly defective. Remove the starter motor and inspect.

Remove the connector from the relay (K01). Is there a voltage of +12 V YES at terminal 86 (white/black) after the starter switch key is operated?

Replace the relay.

NO Check the starter motor safety relay (K3). Can one hear the relay operate after operating the reverse travel lever? NO Remove the connector from relay K3. Is there a voltage of +12 V at terminal 86 (white/black) after the reverse travel lever is operated?

YES

Replace the relay.

NO Are the cable wires of the reverse travel lever properly connected? YES Does the reverse travel lever switch operate correctly?

NO

Reconnect the wires to the switch.

NO

Replace the switch.

NO

Check the main power supply between the battery and the starter motor key. Pin 2 (red wire) of the ignition key connector.

YES Are the indicators on the instrument panel correctly lighted after operating the key switch? YES Are the cable wires of the key switch connected correctly? YES Replace the key switch.

NO Reconnect the wires to the key switch.

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STARTER MOTOR TROUBLE The starter motor does not run (the magnetic switch makes no operating noise).

The starter motor does not run (the magnetic switch makes an operating noise).

CAUSE

ACTION

Too low specific density and battery level.

Inspect the battery.

Poor ignition switch system connection or contact.

Replace the wiring harness and the ignition switch.

Malfunction of the coil or of the magnetic switch pull-in piston.

Replace the magnetic switch.

Too low specific density and battery level.

Inspect the battery.

Poor start-up system contact.

Repair the wiring harness.

Poor magnetic switch contact.


Motor malfunction (e.g. short circuit, brush wear).

Repair or replace the motor assembly.

The starter motor runs too slowly. Poor magnetic switch contact.


Motor malfunction (e.g. short circuit, brush wear).

Repair or replace the motor assembly.

The pinion gear does not engage with the ring gear.

Repair or replace the clutch and the control lever.

Sliding clutch.

Replace the clutch.

Anomalous bushing wear.

Replace the bushing.

Wear on pinion gear or ring gear tooth tips.

Replace the clutch and the ring gear.

Poor pinion gear sliding.

Lubricate or replace the clutch.

The pinion gear springs.

Poor ignition switch return.

Replace the ignition switch.

Field coil loss.

Pinion gear disengagement fault caused by a coil short circuit in the magnetic switch.


The starter motor running cannot crank the engine.

Anomalous noise.

Magnetic switch coil burnt, etc.


135

ALTERNATOR TECHNICAL SPECIFICATIONS Rated voltage ............................................................................................................................................ 14.5 V Current ...................................................................................................................................................... 120 A Swing speed ........................................................................................................................ 12000 ÷ 13500 rpm Operating temperature ...................................................................................... -30 °C ÷ 90 °C (-435 ÷ 1305 °F) Direction of rotation .................................................................................... Clockwise seen from the pulley side Regulated voltage at 5000 rpm with 10 A at 25 °C (362 °F) .......................................................... 14.2 ÷ 14.8 V Maximum load that can be applied at terminal L ........................................................................ 12 V, 3.4 W x 6

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OPERATION The alternator, installed on the motor, on the front RH side of the vehicle, is driven by the crankshaft pulley with the help of a belt. The alternator contains built-in regulators. Current draw on the starter motor system: When the ignition key is turned, a current of low intensity is sent by the battery to the field winding of the rotor (terminal IG). At this stage, the indicator lamp (terminal L) turns on and the rotor is partially magnetized. When the motor starts and the partially magnetized rotor rotates inside the stator, a three-phase alternating current is generated (terminal B+). A constant portion of this current is transformed into a direct current by three excitation diodes installed in the rectifier. The direct current is sent as reinforcement through the field winding of the rotor. Using this method an increase in the magnetic field of the rotor is obtained, as well as a rapid rise in the voltage and current generated at the output. The luminosity of the indicator lamp decreases when the voltage generated at the output is increasing (terminal L). The indicator lamp goes out when the voltage at terminal “L” is equal to that of the battery. The voltage continues to increase up to the value predefined by the regulator. In case the alternator belt is broken, the voltage does not accumulate in the alternator and the load indicator lamp remains lighted to indicate the problem.

1. Terminal W 2. Terminal IG 3. Terminal L 4. Terminal B


137

TROUBLESHOOTING TROUBLE

Not recharged.

Recharge insufficient.

Excessive recharge.

CAUSE

ACTION

Recharging system interrupted (warning lamp, fuse, connector, etc.).

Check the connections of the recharging system, clean and tighten the alternator and battery terminals.

Voltage regulator inefficient.

Replace the part.

Rotor winder interrupted.

Replace the part.

Worn brushes.

Replace the part.

Slackened fan belt.

Supply the correct voltage.

Voltage regulator faulty.

Replace the part.

Excessive wear of rotor rings or brushes.

Replace the part.

Short-circuited diodes.

Replace the part.

Short-circuited stator winders or rotor winder.

Replace the part.

Loose system connections.

Check the connections of battery terminals, starter motor terminals and alternator.

Voltage regulator inefficient.

Replace the part

Ground connection faulty.

Check connections for leaks.

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BATTERY For the loader backhoe models two different kinds of installation are provided: - with one battery; - with two batteries (for cold climates).

TECHNICAL SPECIFICATIONS Single battery Voltage: ........................................................................................................................................................12 V Capacity (20 h):.......................................................................................................................................... 95 Ah Discharge current: ...................................................................................................................................... 900 A Weight with electrolyte: ................................................................................................................... 25 kg (55 lb) Double battery Voltage: ........................................................................................................................................................12 V Capacity (20 h):.......................................................................................................................................... 60 Ah Discharge current: ...................................................................................................................................... 600 A Weight with electrolyte: ................................................................................................................ 17 kg (37.5 lb)

OPERATION All models feature one or two 12 V, negative ground, “maintenance free” lead calcium (Pb-Ca) type battery.

The battery is constructed in such a manner that each cell contains positive and negative plates placed alternatively next to each other.

IMPORTANT: “Maintenance Free” means that under normal charging conditions the battery does not lose water from the electrolyte. Conditions that may cause water loss include prolonged charging above 14.4 V where gassing occurs as it approaches full charge. This can be caused by a faulty charging system or boost/recovery charging equipment. The battery has four major functions:

Each positive plate is separated from a negative plate by a non conducting porous envelope separator.

- to provide a source of current for starting, lighting and instrumentation; - to help control the voltage in the electric system; - to provide current when the electric consumption exceeds the alternator output; - to support quiescent loads from radio and microprocessor memory.

If any of the positive plates should make contact with negative plates within a cell, the cell will short circuit and suffer irreparable damage. All of the positive plates are welded to a bus-bar, forming a positive terminal and all of the negative plates are welded to a similar bus-bar forming a negative terminal. Each positive plate is composed of a lead grid with lead peroxide pasted into the grid openings. The negative plates are composed of a lead grid with spongy lead pasted into the grid openings. The plates are submerged in a liquid electrolyte solution of diluted sulphuric acid.

Copyright © SECTION 55 - ELECTRIC SYSTEM REPLACEMENT Move the machine to a level and firm ground. Lower the loader attachment to the ground. Place the backhoe attachment in the road travel position. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Stop the engine and remove the starter key.

WARNING Never reverse the battery terminals. Connect the positive cable to the positive terminal (+) and the negative cable to the negative terminal (-). When disconnecting the battery cables, always disconnect the negative cable (-) first. When reconnecting the battery cables, always connect the negative (-) cable last. Never short-circuit the battery terminals with metal objects. Never touch the battery terminals with your hands. This could generate an electrolysis inside the human body and damage the body’s vital organs. Place the battery switch in the OFF position. Remove the battery master switch support (6) without disconnect the battery cables. Remove the terminal covers and disconnect the cables, first from the negative terminal (1) then the positive terminal (2). Remove the nuts and washers (3), the clamping bar (4) and the brackets (5) and remove the old battery. Install the new battery. Install the brackets (5), the clamping bar (4) and the washers and nuts (3). Clean the cables and the connecting terminals and coat them with grease. Connect the cables, first to the positive terminal (2), then the negative terminal (1) and install the terminal covers. Reassemble the battery master switch support (6).

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Copyright © 140


CHARGE AND ELECTROLYTE LEVEL CHECK WARNING

WARNING

The battery electrolyte generates severe burns. The battery contains sulphuric acid. Avoid any contact with the skin, eyes or clothing.

Before carrying out any welding on the machine or repair work on the electric circuit, disconnect the battery and disconnect the B+ and D+ wires on the alternator. When reconnecting, check the wire markings.

Antidote: EXTERNAL: rinse well with water, removing any soiled clothing.

CHARGE CHECK

INTERNAL: avoid vomiting. Drink water to rinse your mouth. Consult a doctor.

Measure the density of the acid of the single cells with a commonly available measuring device.

EYES: rinse thoroughly with water for 15 minutes and get prompt medical attention.

The measured values (see table below) indicate the charge status of the battery.

When working with batteries, always wear gloves, protection goggles and suitable clothes.

When measuring, the temperature of the acid should be +20 °C (68 °F), if possible.

WARNING

ELECTROLYTE CONCENTRATION

Never touch the battery terminals with your hands. This could generate an electrolysis inside the human body and damage the body’s vital organs.

WARNING Batteries produce explosive gases. To prevent any risk of explosion, observe the following instructions:

in kg/dm3 (lb/ft3)

Charge

Normal

Tropical

1.28 (80)

1.23 (77)

good

1.20 (75)

1.12 (70)

reduced: charge

1.12 (70)

1.08 (67)

low: immediately charge

- place the battery switch in the OFF position; - when disconnecting the battery cables, always disconnect the negative cable (-) first; - when reconnecting the battery cables, always connect the negative (-) cable last; - never short-circuit the battery terminals with metal objects; - do not weld, grind or smoke near a battery. Keep open flames away and do not smoke near batteries. Always provide good ventilation when charging a battery or using a battery in an enclosed space.

ELECTROLYTE LEVEL CHECK Remove the vent plugs and check the level in each battery cell. The level should come up to 6 mm (0.24 in) above the separator plates. Add distilled water if necessary.


141

CONNECTING A BOOSTER BATTERY WARNING When the electrolyte of a battery is frozen, it can explode if you attempt to charge the battery or if you try to start the engine using a booster battery. Always keep the battery charged to prevent the electrolyte freezing.

WARNING Connecting jumper cables wrongly or shortcircuiting battery terminals can cause an accident. Connect the jumper cables following the instructions in this manual. IMPORTANT: make sure that the voltage of the booster batteries is the same as that of the machine system (12 V). Open the battery box and then remove the tool box. Remove the terminal covers. Connect the positive (+) jumper cable to the positive (+) terminal of the machine’s battery. Connect the negative (-) jumper cable to one of the fastening screws (1) of tank. Start the engine First disconnect the negative (-) jumper cable, then disconnect the positive (+) jumper cable from the booster battery. Install the terminal covers. Install the tool box and close the battery box.

BATTERY MASTER SWITCH WARNING The battery master switch must be switched off at the end of each working day, for machine service or for any operations on the electric system. It acts as an anti-theft device when the cab doors and windows are locked. The battery master switch (1) is located in the battery compartment and is used to completely disconnect the battery from the electric system. When the battery master switch has an inclination of 45°, the circuit is disconnected. When the master switch is in vertical position, the circuit is connected.

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TROUBLESHOOTING TROUBLE The electric system is inoperative.

Starter motor speed too low, the engine cranks slowly.

Starter motor inoperative.

The charge indicator lamp stays on with the engine running.

POSSIBLE CAUSE

ACTION

Loose or oxidised battery connections.

Check that the battery voltage with open circuit is at least 12.6 V.

Clean and tighten the connections. Sulphated batteries.

Check the electrolyte level and density.

Battery isolator switch off.

Restore the battery isolator switch.

The main connection fuse of the machine is blown.

Find the reason of the failure and replace the connection fuse.

Loose or corroded connections.

Clean and tighten loose connections.

Low battery output voltage.

Check that the battery voltage with open circuit is at least 12.6 V. Check the electrolyte level and density.

Incorrect viscosity of the engine oil.

Use an oil with correct viscosity for the temperature conditions.

Transmission gearshift lever engaged.

Move gearshift lever to neutral.

Loose or corroded connections.

Clean and tighten loose connections.

Dead batteries.

Charge or replace the batteries.

Low engine idle speed.

Increase idle speed.

Loose belt.

Check belt tension.

Malfunctioning battery.


Malfunctioning alternator.

Check the alternator and repair, if necessary.


TROUBLE Batteries will not charge.

The charge indicator flashes, indicating excessive charging voltage.

POSSIBLE CAUSE

143

ACTION

Loose or corroded battery connections.

Clean and tighten the connections.

Sulphated batteries.


Loose or worn belt.

Check the automatic belt tensioner. If necessary, replace the belt.

Malfunctioning alternator.

Check the alternator and repair, if necessary.

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NOTES:


Copyright ©

580T 580ST 590ST 695ST

SECTION 82 - LOADER ATTACHMENT LOADER ATTACHMENT CONTROLS............................................................................................................. 3 LOADER ATTACHMENT OPERATION ...................................................................................................... 3 4x1 LOADER BUCKET CONTROL (Optional) ............................................................................................ 6 LOADER ATTACHMENT CONTROL LOCK (Specific to certain countries)................................................ 7 BUCKET SELF-LEVELLING............................................................................................................................. 8 LOADER ATTACHMENT SAFETY STRUT...................................................................................................... 9 LOADER ATTACHMENT SAFETY STRUT (2WS) ..................................................................................... 9 LOADER ATTACHMENT SAFETY STRUT (4WS) ................................................................................... 10 REMOVAL AND INSTALLATION OF LOADER BUCKET.............................................................................. 11 STANDARD LOADER BUCKET................................................................................................................ 11 LOADER BUCKET WITH FORKS (Optional) ............................................................................................ 12 BUCKET TEETH REPLACEMENT............................................................................................................ 13 LOADER REMOVAL....................................................................................................................................... 14

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SECTION 82 - LOADER ATTACHMENT

Copyright © SECTION 82 - LOADER ATTACHMENT

LOADER ATTACHMENT CONTROLS WARNING Before starting the engine, make sure you are fully aware of the location and the function of each control. Operating the controls wrongly can cause serious physical injury.

WARNING Before using the controls make sure that the operator’s seat is correctly adjusted in the loader attachment position. WITH STANDARD LOADER BUCKET Located on the right of the steering wheel, this nine position lever operates all the loader attachment controls. The speed of movement of each control depends on the angle to which the lever is tilted. In the intermediate position, two movements can be obtained simultaneously. WITH 4x1 LOADER BUCKET The function of the lever is identical to that of the machine fitted with the standard loader bucket, with the addition of the clam control.

LOADER ATTACHMENT OPERATION NEUTRAL AND HOLD With the lever in the neutral/hold position (0), the attachment movement can be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped.

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RAISING THE LOADER ATTACHMENT With the lever in position (1), the attachment rises.

LOWERING THE LOADER ATTACHMENT With the lever in position (2), the attachment lowers.

LOADER BUCKET FLOAT CONTROL With the lever in position (3), the bucket follows the contours of the ground without it being necessary to operate the lever. NOTE: in this position the lever does not automatically return to neutral when it is released. It is necessary to move it manually.

Copyright © SECTION 82 - LOADER ATTACHMENT FILLING THE LOADER BUCKET With the lever in position (4), the bucket rolls back (fills).

DUMPING THE LOADER BUCKET With the lever in position (5), the bucket rolls forward (dumps).

AUTOMATIC RETURN TO LOADER BUCKET FILLING With the lever in position (6), the attachment lowers and, simultaneously, the bucket places itself to the digging position. NOTE: it is possible to adjust the tilt angle for bucket filling.

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4x1 LOADER BUCKET CONTROL (Optional) This control operates the opening and closing of the 4x1 bucket clam. This control is proportional: When releasing the roller (7), it automatically returns to the initial position (neutral) and the bucket remains in the position where it was when movement stopped. When shifting the roller (7) forward: the loader bucket clam closes (A). When shifting the roller (7) backward: the loader bucket clam opens (B). 4x1 loader bucket control roller detent procedure The operator may install a detent position for the 4x1 bucket operation. This position alters operation in order to allow the operator to lock the switch in the open circuit position, so that this position is held until the operator unlocks the switch. The standard position of the switch is with the open U shape pointing upwards. In this configuration, the switch will automatically spring back to the neutral position when released, from any position. To set the detent position to the bucket open position, it is necessary to remove the top of the switch, rotating it by 180°. Remove the screw (2) of the roller (1) using a small phillips screwdriver.

Copyright © SECTION 82 - LOADER ATTACHMENT Lift and remove the top portion (3) of the roller switch, rotate it by 180° and tighten the screw in the top portion of the roller. NOTE: the open U shape must point downwards. Carefully restore the screw (2) into place and do not overtighten. Test the switch by lifting it up into detent position before restoring the cap into place. The switch should lock into position. In this condition, the 4x1 loader bucket control roller is locked. To unlock it, it is necessary to rotate the top portion again and take it back to its initial position.

LOADER ATTACHMENT CONTROL LOCK (Specific to certain countries) This pin (1), located next to the control lever, is used to lock the attachment controls. To lock the controls, extract the pin from its housing and insert it into the specially provided hole of the lever support.

WARNING Before leaving the operator’s compartment, undertaking any road travel or working with the backhoe attachment, place the pin in locking position.

7

Copyright © 8


BUCKET SELF-LEVELLING SELF-LEVELLING ADJUSTMENT The “return to dig” device is an electrically activated feature which enables the operator to automatically return the bucket to a level digging position for a further work cycle, with one simple movement of the control lever (3). Whenever the bucket is rolled forward to dump the return to dig electric circuit is completed and the solenoid on the bucket spool is energised. When the loader bucket control lever (3) is moved diagonally left to the return to dig position (2) the electromagnet will hold the bucket spool in the roll back position until the bucket is in the level digging position at which time the indicator on the rod of the bucket linkage will pass in front of the sensor which de-energises the electromagnet on the bucket spool enabling the spool to return to the neutral position.

RETURN TO DIG SENSOR - ADJUSTMENT The return to dig device consists of an electromagnet mounted on the loader bucket control valve spool, a sensor (1) mounted on top of the loader arm and a pointer attached to the tube of the bucket self-levelling linkage. Place the bucket on the ground in the preferred digging position. Check the dimensions of 88.5 mm (3.5 in) and 7.5 mm (0.3 in) are maintained as shown. Make sure that the sensor (1) is 6 mm (0.24 in) from the tie rod (2). As a visual aid for the operator, while seated in the cab, the pointer mounted on the loader arm can be seen to align with the pointer on the return to dig linkage, when the loader arms are lowered and the bucket is in the level digging position.


LOADER ATTACHMENT SAFETY STRUT Located on the left-hand side of the loader attachment, this safety strut enables the loader attachment to be locked in the raised position in case of defects in the system.

LOADER ATTACHMENT SAFETY STRUT (2WS) LOCKED POSITION Completely raise the loader attachment. Stop the engine and remove the starter switch key. Remove the split pin (3) to extract the pin (2).

Raise the loader attachment to the desired position. Now the safety strut (1) is free and positions itself onto the cylinder rod, thus locking it. As a safety precaution, position the pin (2) into the relevant hole (4) in the safety strut (1).

UNLOCKED POSITION Extract the pin (2) from the hole (4) in the safety strut (1). Lower the loader attachment. Place the safety strut (1) to storage position: align the holes of the safety strut (1) and bracket (5) and assemble the pin (2). Fasten the pin (2) by installing the split pin (3).

9

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LOADER ATTACHMENT SAFETY STRUT (4WS) LOCKED POSITION Completely raise the loader attachment. Stop the engine and remove the starter key. Remove the split pins (1) and the safety strut (2) from the arm. Put the split pins back in place. Place the strut (2) on the cylinder rod and fasten it by means of the fastening flip (3).

WARNING It is mandatory to install the safety strut when carrying out any operation requiring the loader attachment to be in the raised position. 1

UNLOCKED POSITION Remove the flip (3) and the strut (2) from the cylinder rod.

2 Install the safety strut (2) on the loader arm by means of the split pins (1). Start the engine and lower the loader attachment.

3


11

REMOVAL AND INSTALLATION OF LOADER BUCKET STANDARD LOADER BUCKET REMOVAL Move the machine to a level and firm ground. Lower the bucket to the ground in dump position (tilted completely forward). Stop the engine and remove the starter key. If the machine is fitted with a 4x1 bucket, release the pressure from the bucket circuit: turn the key to ON (with engine stopped) and operate the accelerator knob. Remove the retaining rings and pins, then drive out the pins (1).

WARNING Always wear eye protection when using a tool which might project metal particles. Use a hammer with a soft face, such as copper, for pins assembly/ disassembly. (4x1 bucket) disconnect and plug the hydraulic supply lines. Start the engine. Operate the attachment controls so as to release the bucket.

4

Reverse the machine from the bucket. INSTALLATION Make sure all bushings are completely clean. Remove any dirt or foreign matter, if necessary. Start the engine. Use the attachment controls to engage the attachment between the bucket lugs. Reinstall the arm/bucket pins (1) and then install the relevant retaining pins and rings. Use the bucket controls to align the connecting rod holes (3) with the bucket lugs. Stop the engine and remove the starter key. (4x1 bucket) release the pressure from the bucket circuit. Install the rod/bucket pins (2) and then install the relevant retaining pins and rings. (4x1 bucket) remove the plugs and reconnect the hydraulic lines.

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LOADER BUCKET WITH FORKS (Optional) WARNING The forks are heavy, so use great care when swinging them into their working and stowage position. INSTALL FORKS IN WORKING POSITION Move the bucket to a level and firm ground. Stop the engine and remove the starter key. Raise the parking brake lever. Remove the retained pin and the pin (1). Lower the fork (2) manually and carefully until it is laying in position against the bucket cutting edge. IMPORTANT: the forks must be laying against the cutting edge of the bucket, and never against bucket teeth.

Install the pin (1) and the safety pin. Repeat the same operations for the other fork. Slide the forks until they are suitably spaced for the intended job. IMPORTANT: the two forks must be positioned at the same distance from the centre of the bucket. IMPORTANT: never use the forks to lift the machine.

WARNING When using the forks with a 4x1 bucket, never attempt to use the bucket jaw opening function.

Copyright © SECTION 82 - LOADER ATTACHMENT INSTALL THE FORKS IN REST POSITION Rest the loader bucket on a level and firm ground. Stop the engine and remove the starter key. Disengage the parking brake lever. Remove the retained pin and the pin (1). Tilt the fork (2) manually and carefully until it is rearwards into transport position.

Reinstall the pin (1) and the safety pin into their housing. NOTE: if necessary, slide the fork to the side to bring it into its housing. Repeat the same operations for the other fork. IMPORTANT: the forks must be securely retained in their proper storage position using the pins and split pins provided for this purpose. If forks are not correctly secured, they can cause serious injury.

BUCKET TEETH REPLACEMENT Move the machine to a level and firm ground. Position the loader bucket so that the bucket teeth can be replaced. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Stop the engine and remove the starter key. Loosen and remove the screws (2) with the nuts (3). Extract the tooth (1). Clean the area around the tooth. Assemble the new tooth (1). Screw in and tighten the screws (2) with the nuts (3).

13

Copyright © 14


LOADER REMOVAL Remove the loader described previously).

bucket

(see

procedure

Fully retract bucket cylinders and raise arm until lift cylinder pivots can be seen above engine guard. Place a suitable stand under the end of the arm to take the weight. Switch off the engine and relieve hydraulic pressure.

Remove the snap rings (2) and the pins, then extract the pins (1). Lower the lift cylinders carefully onto the chassis.

Remove the snap rings (3) and drive out the pins (4). Lower the arms onto the lift cylinders.

Disconnect and cap the lift cylinder hoses (5) at the top of the loader arm on each side of the machine and disconnect the return to dig sensor cable (7) on the right hand side. If the 4x1 bucket is fitted disconnect and cap hose (6) on each side of the loader.

Copyright © SECTION 82 - LOADER ATTACHMENT Support loader using a suitable sling.

Remove the snap ring and the pin, then extract the pin (8).

Remove the loader attachment from the machine.

INSTALLATION For installation, follow the removal procedure in reverse order.

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NOTES:


Copyright ©

580T 580ST 590ST 695ST

SECTION 84 - BACKHOE ATTACHMENT DESCRIPTION AND OPERATION................................................................................................................... 3 BACKHOE ATTACHMENT CONTROLS .......................................................................................................... 6 BACKHOE ATTACHMENT MECHANICAL CONTROLS ............................................................................ 7 BACKHOE ATTACHMENT HYDRAULIC CONTROLS ............................................................................. 18 BACKHOE ATTACHMENT SIDESHIFT (Sideshift version) ...................................................................... 24 BACKHOE ATTACHMENT DISASSEMBLY .................................................................................................. 26 BACKHOE BUCKET REPLACEMENT...................................................................................................... 28 BACKHOE BUCKET.................................................................................................................................. 29 BACKHOE ATTACHMENT HYDRAULIC HANDLING ................................................................................... 30 CONTROLS ............................................................................................................................................... 30 HYDRAULIC DIAGRAM ............................................................................................................................ 31 DISASSEMBLY AND ASSEMBLY............................................................................................................. 32

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SECTION 84 - BACKHOE ATTACHMENT

Copyright © SECTION 84 - BACKHOE ATTACHMENT

DESCRIPTION AND OPERATION Backhoe loaders are available with center pivot or (only 695ST) sideshift backhoe attachment. On sideshift machines the backhoe is attached to a carriage hydraulically clamped to the machine frame. This allows the operator to reposition the carriage on the frame and to adjust the position of the backhoe attachment to suit the operating conditions. The machine is raised using two vertical stabilisers attached to each side of the machine.

On center pivot machines, the backhoe attachment pivots around a fixed central point on the rear side of the machine. Independently operated stabilizers are attached to the base of the chassis and pivot about an arc to raise or lower each side of the machine.

Each stabilizer is independently operated using: - levers (1) and (2) on mechanical control backhoe loaders;

3

Copyright © 4


- control levers (3) and (4) on “pilot” control backhoe loaders.

The backhoe attachment is locked in position during transport using a hydraulically operated lock which acts on the hook (5).

The lock is activated by the switch (7).

The backhoe on the mechanical control models is controlled using two main control levers. There are three configuration types for 2-lever control systems (7) and (8), as described in the following pages. A 4-lever system installed by the Dealer is also available as optional accessory.

Copyright © SECTION 84 - BACKHOE ATTACHMENT The backhoe attachment on the hydraulic control models is controlled using two rear hydraulic control levers (9) and (10).

Machines may be fitted with an optional telescopic dipper which can be operated simultaneously with other boom, dipper and bucket movements.

The telescopic dipper on the manually controlled models is controlled by a pedal (11) located in the rear part of the cab.

The telescopic dipper on pilot control modes is controlled using the two buttons (12) and (13) on the left hydraulic control lever.

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Copyright © 6


BACKHOE ATTACHMENT CONTROLS NOTE: the instruments represented may not exactly correspond to the instruments on your machine. IMPORTANT: before using the backhoe attachment, make sure that the sideshift carriage locking switch (1) is in the OFF position and that the lock hook has been disengaged, either by means of the lever (3) or the switch (2). IMPORTANT: whenever the backhoe attachment is used, the machine must be resting on the stabilizers.

WARNING Check control functions before operating the machine. Failure to check control pattern before operating can cause unexpected machine movement, death or serious injury.

WARNING Any uncontrolled movement of the machine can cause an accident. Before turning the operator’s seat to the backhoe attachment working position, it is essential to place the direction-of-travel control lever and the powershuttle gearshift lever in the neutral position and immobilize the machine by means of the parking brake lever.

WARNING Before using the backhoe controls, make sure that the operator’s seat is correctly adjusted in the backhoe attachment position.

Copyright © SECTION 84 - BACKHOE ATTACHMENT BACKHOE ATTACHMENT MECHANICAL CONTROLS STABILIZER MECHANICAL CONTROLS IMPORTANT: whenever the backhoe attachment is used, the machine must be resting on the stabilizers. Left-hand stabilizer left-hand control lever This lever has three positions: Position (0): neutral. This position stops the movement of the left-hand stabilizer. As soon as the lever is released, it automatically returns to the neutral position (0) and the left-hand stabilizer stops raising or lowering. Position (1): the left-hand stabilizer lowers. Position (2): the left-hand stabilizer rises. Right-hand stabilizer right-hand control lever This lever has three positions: Position (0): neutral. This position stops the movement of the right-hand stabilizer. As soon as the lever is released, it automatically returns to the neutral position (0) and the right-hand stabilizer stops raising or lowering. Position (1): the right-hand stabilizer lowers. Position (2): the right-hand stabilizer rises. NOTE: to raise or lower the two stabilizers at the same time, operate the two levers simultaneously. IMPORTANT: before machine travel or before using the loader attachment, make sure the stabilizers are completely raised. During road travel, the stabilizers must be completely raised and immobilized by means of the pins provided for that purpose. Locking the stabilizer mechanical controls (specific to certain countries) This pin (1), located in front of the stabilizer control levers, is used to lock the stabilizer controls. To lock the controls, extract the pin from its housing and insert it into the specially provided hole of the lever support.


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ATTACHMENT MECHANICAL CONTROLS These control levers are used to operate the backhoe attachment. The speed of movement of each control depends on the angle to which the lever is tilted. In the intermediate position, two movements can be obtained simultaneously. Four backhoe attachment control configurations exist, depending on the country concerned: - standard configuration; - ISO configuration; - four lever pattern configuration; - cross-pattern configuration. The operating pattern of the control levers is different. Check which configuration you have on your machine. Standard configuration Backhoe boom and backhoe attachment swing lefthand control lever This lever has five positions: Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped. Position (A): the boom lowers. Position (B): the boom rises. Position (C): the backhoe attachment swings to the left. Position (D): the backhoe attachment swings to the right. Backhoe dipper and backhoe bucket right-hand control lever This lever has five positions: Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped. Position (E): the backhoe dipper extends. Position (F): the backhoe dipper retracts. Position (G): the backhoe bucket closes. Position (H): the backhoe bucket opens.


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ISO configuration Backhoe dipper and backhoe attachment swing lefthand control lever This lever has five positions: Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped. Position (A): the backhoe dipper extends. Position (B): the backhoe dipper retracts. Position (C): the backhoe attachment swings to the left. Position (D): the backhoe attachment swings to the right. Backhoe boom and backhoe bucket right-hand control lever This lever has five positions: Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped. Position (E): the boom lowers. Position (F): the boom rises. Position (G): the backhoe bucket closes. Position (H): the backhoe bucket opens.


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Four-lever pattern configuration Lever (1) for dipper This lever has three positions: Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped. Position (A): the backhoe dipper extends. Position (B): the backhoe dipper retracts. Lever (2) for boom This lever has three positions: Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped. Position (C): the boom rises. Position (D): the boom lowers. Lever (3) for backhoe bucket This lever has three positions: Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped. Position (E): the backhoe bucket closes. Position (F): the backhoe bucket opens. Lever (4) for backhoe attachment swing This lever has three positions: Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped. Position (G): the backhoe attachment swings to the right. Position (H): the backhoe attachment swings to the left.


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Cross-pattern configuration Backhoe boom and backhoe attachment swing lefthand control lever This lever has five positions: Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped. Position (A): the boom lowers. Position (B): the boom rises. Position (C): the backhoe attachment swings to the left. Position (D): the backhoe attachment swings to the right. Backhoe dipper and backhoe bucket right-hand control lever This lever has five positions: Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as the lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped. Position (E): the backhoe dipper extends. Position (F): the backhoe dipper retracts. Position (G): the backhoe bucket closes. Position (H): the backhoe bucket opens.


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TELESCOPIC DIPPER MECHANICAL CONTROL PEDAL (If fitted) This pedal (A) has three positions: Position (0): neutral. This position enables the movement of the telescopic dipper to be stopped. This position is selected automatically, as soon as the pedal is released. Position (1): the telescopic dipper extends. Position (2): the telescopic dipper retracts. Before using this pedal make sure that the telescopic dipper is mechanically unlocked. NOTE: operating the backhoe attachment control levers and this pedal simultaneously will enable numerous possibilities of progressive functioning. AUXILIARY ATTACHMENT CONTROL PEDAL (Optional) This pedal (1) is located to the right of the backhoe attachment controls and is used for operating the auxiliary attachment, such as a hydraulic hammer.

Copyright © SECTION 84 - BACKHOE ATTACHMENT BACKHOE ATTACHMENT MECHANICAL CONTROL LOCK (Specific to certain countries) This pin (1), located in front of the stabilizer control levers, is used to lock the backhoe attachment controls.

To lock the controls, extract the pin from its housing and insert it into the specially provided hole of the lever support.


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BACKHOE ATTACHMENT HYDRAULIC CONTROLS

1. CONTROL ENABLE SWITCH: when set to ON (control lamp on), this switch allows enabling all hydraulic controls of the backhoe attachment. 2. LEFT-HAND HYDRAULIC CONTROL LEVER: the left-hand hydraulic control lever controls attachment swing and the boom or the dipper (depending on the control pattern adopted).

6. TELESCOPIC DIPPER CONTROLS: (proportional controls): press the right-hand button to extend the telescopic dipper. Press the left-hand button to retract the telescopic dipper. 7. WRIST RESTS: the wrist rests may be adjusted to the required height.

3. RIGHT-HAND HYDRAULIC CONTROL LEVER: the right-hand hydraulic control lever controls the bucket and the boom or the dipper (depending on the control pattern adopted).

8. HYDRAULIC CONTROL LEVER SUPPORT ANGLE ADJUSTMENT: these controls are used for the fore/aft and left/right adjustment of the arm.

NOTE: the operating speed depends on the angle of movement of the control levers. In intermediate position, two movements may be obtained simultaneously.

9. HORN BUTTON (momentary action control).

4. STABILIZER CONTROLS: the right-hand control is for the right-hand stabilizer and the lefthand control is for the left-hand stabilizer.

11. DECELERATOR BUTTON: by pressing this button, the engine rpm sets to low idle. During this phase, the accelerator knob and pedal are disabled. By pressing the button again, the engine rpm is restored and the accelerator knob and pedal are functional again.

5. CONTROL PATTERN CHANGE SWITCH: this switch is used for changing the standard control pattern to the ISO pattern.

10. CONTROLS OF AUXILIARY BIDIRECTIONAL ATTACHMENT (If fitted): proportional buttons for the activation of the additional attachment.

Copyright © SECTION 84 - BACKHOE ATTACHMENT CONTROL ENABLE SWITCH This control is located on the right-hand control lever. This switch has three positions: - position OFF: (lamp off) all controls will deactivate; - position (1): by pressing the upper side (lamp off), the stabilizers will activate; - position (2): by pressing the upper side (lamp on) again, all controls will activate.

WARNING After using the attachment or before leaving the machine, always tilt the switch to OFF by pressing the lower side of the switch (lamp off). Never forget this basic safety requirement. NOTE: when starting the engine, the position OFF for disabled controls is automatically selected.

CONTROL PATTERN CHANGE SWITCH (BOOM OR DIPPER) Located on the right-hand hydraulic control lever, this switch is fitted with a locking device. The switch is used to change from standard pattern to ISO version, or vice versa. To unlock the switch, push the locking device upwards and at the same time press the top of the switch (1). In this position, the switch turns on and the controls are in ISO pattern. The boom and dipper controls on the hydraulic control levers are now inverted. Press the bottom of the switch (1) to lock and return to standard pattern operation.

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BACKHOE ATTACHMENT HYDRAULIC CONTROLS Standard configuration Backhoe boom and backhoe attachment swing lefthand hydraulic control lever This hydraulic control lever has five positions: Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as the hydraulic control lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped. Position (A): the boom lowers. Position (B): the boom rises. Position (C): the backhoe attachment swings to the left. Position (D): the backhoe attachment swings to the right.

Backhoe dipper and backhoe bucket right-hand control lever This hydraulic control lever has five positions: Position (0): neutral/hold. This position enables the attachment movement to be stopped. As soon as the hydraulic control lever is released, it automatically returns to the neutral position (0) and the attachment remains in the position where it was when movement stopped. Position (E): the backhoe dipper extends. Position (F): the backhoe dipper retracts. Position (G): the backhoe bucket closes. Position (H): the backhoe bucket opens.

Copyright © SECTION 84 - BACKHOE ATTACHMENT STABILIZER HYDRAULIC CONTROLS These controls are located on the left-hand hydraulic control lever and may be operated independently or simultaneously. These controls are proportional, and therefore, the stabilizer speed may vary. IMPORTANT: whenever the backhoe attachment is used, the machine must be resting on the stabilizers.

Left-hand stabilizer left-hand control lever This lever has four positions: Position (0): neutral. This position stops the movement of the left-hand stabilizer. As soon as the lever is released from positions (1) or (2), it automatically returns to the neutral position (0) and the left-hand stabilizer stops raising or lowering. When held in position (1): the left-hand stabilizer lowers. When held in position (2): the left-hand stabilizer rises. Position (3): stabilizer auto-up feature.

Right-hand stabilizer right-hand control lever This lever has four positions: Position (0): neutral. This position stops the movement of the right-hand stabilizer. As soon as the lever is released from positions (1) or (2), it automatically returns to the neutral position (0) and the righthand stabilizer stops raising or lowering. When held in position (1): the right-hand stabilizer lowers. When held in position (2): the right-hand stabilizer rises. Position (3): stabilizer auto-up feature.

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Auto-up feature (Center pivot version) (Optional) Position (3): when the levers are momentarily pulled back to this position and then released, they return to the neutral position and the stabilizers automatically rise to road travel position, thereby leaving your hand free for other duties. To stop the automatic rise at any time, push or pull the levers; the rise of the stabilizers stops. NOTE: the machines not provided with the optional auto-up feature still have the relevant detent position, but this does not affect the stabilizer operation in any way. IMPORTANT: before machine travel or before using the loader attachment, make sure the stabilizers are completely raised. IMPORTANT: during road travel, the stabilizers must be completely raised and immobilized by means of the pins provided for that purpose. TELESCOPIC DIPPER CONTROLS (Optional) Press and hold down the right-hand button (1) to extend the telescopic dipper. As soon as the button is released the dipper stops and remains in the position it occupied when the button was released. Press and hold down the left-hand button (2) to retract the telescopic dipper. As soon as the button is released the dipper stops and remains in the position it occupied when the button was released. By pressing button (3), it is possible to set the engine rpm to idle run disabling accelerator handle and accelerator pedal. By pressing again button (3) the engine rpm are restored and the accelerator handle and accelerator pedal as well. Before using these controls, make sure the telescopic dipper is mechanically unlocked. NOTE: operating the backhoe attachment control levers and these controls simultaneously will enable numerous possibilities of progressive functioning.

Copyright © SECTION 84 - BACKHOE ATTACHMENT AUXILIARY BI-DIRECTIONAL CONTROLS (Optional) Press and hold the left-hand button (1) to let the oil flow out of the left-hand side of the boom. Press and hold the left-hand button (2) to let the oil flow out of the right-hand side of the boom.

HYDRAULIC CONTROL LEVER SUPPORT ADJUSTMENTS Fore and aft Press the two levers (1), then tilt the hydraulic control levers to the desired position. Once the desired position is reached, release the two levers (1).

Left and right Loosen the two knobs (2) located in front of each hydraulic control lever support, then tilt the supports to the required position. Once the adjustment has been carried out, tighten the two knobs (2).

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BACKHOE ATTACHMENT SIDESHIFT (Sideshift version) To dig alongside a building or fence, etc., it is possible to shift the backhoe attachment sideways to the right or the left. MECHANICAL HANDLING Place the backhoe attachment to the left if you want to shift the attachment to the right, or place it to the right if you want to shift it to the left, then place the attachment on the ground. Press the backhoe attachment sideshift unlocking switch (1). The switch lamp turns on (ON position). (A) Version with mechanical engines (B) Version with electric engines

Operate the backhoe attachment controls alternately so as to slide the sideshift carriage sideways. Once the attachment is in the side position required, swing it round into alignment with the machine. Work on the opposite side of the sideshift carriage as much as possible. Otherwise, reduce the load in the bucket for better stability. Press the backhoe attachment sideshift locking switch (1). The switch lamp turns off (OFF position). IMPORTANT: except when the sideshift carriage is being moved, the switch (1) must always be in the OFF position. Never use the backhoe attachment with the sideshift carriage unlocked.

Copyright © SECTION 84 - BACKHOE ATTACHMENT HYDRAULIC HANDLING Press the backhoe attachment sideshift unlocking switch (1). The switch lamp turns on (ON position). (A) Version with mechanical engines (B) Version with electric engines

For handling, press: - the button (2) side with the symbol to move the backhoe attachment to the left side of the track; - the button (2) side without symbol to move the backhoe attachment to the right side of the track. NOTE: track sides are referred to the travel direction of the machine. Press the backhoe attachment sideshift locking switch (1). The switch lamp turns off (OFF position). IMPORTANT: except when the sideshift carriage is being moved, the switch (1) must always be in the OFF position. Never use the backhoe attachment with the sideshift carriage unlocked.

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BACKHOE ATTACHMENT DISASSEMBLY Park the machine on a flat surface and position the backhoe on the ground.

WARNING Always support the structural members so that they will be stable and safe to work around.

Lower stabilizers sufficiently and however ensure that the rear tyres are in contact with the ground to remove the weight from the rear wheels. IMPORTANT: the rear wheels must remain in contact with the ground.

Fully retract dipper cylinder and lower boom until bucket is firmly resting on the ground. Support the backhoe using suitable stand and hoist capable of carrying 1500 Kg (3307 lb). Turn off engine, then move backhoe control levers through all operating positions to relieve pressure in the system. Re-check that backhoe elements are fully supported. Disconnect all hoses that travel through the swing bracket reach the backhoe.

Copyright © SECTION 84 - BACKHOE ATTACHMENT Disconnect the yoke of the lock cylinder (1) for transport from the hook (2).

Extract the pin (3). Remove the hook (2) and the hook (4). Now remove the pins (5) and (6) by tapping with a hammer on one side and extracting the pins from the other. Thus the boom cylinder rod has been released.

Loosen and remove the screw (7) with the relevant washer (8). Remove the retaining plate (9). Extract the pin (10) with a hammer.

Now it is possible to remove the backhoe attachment from the machine.

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BACKHOE BUCKET REPLACEMENT REMOVAL Move the machine to a level and firm ground. Lower the stabilizers until they are resting on the ground. Place the bucket on the ground. Stop the engine and remove the starter key. Remove the snap ring (1) and the ring (2). Slide out the pin (3).

WARNING Always wear eye protection when using a tool which might project metal particles. Restart the engine. Operate the backhoe attachment controls so that the hook (4) releases from the pin (5). Stop the engine and remove the starter key.

INSTALLATION Start the engine. Slowly approach the arm to the backhoe bucket paying attention that hook (4) engages in the bucket pin (5). Move the arm so that the pin hole (3) aligns with the holes of the bucket lugs. Stop the engine and remove the starter key. Insert pin (3) and install the stop ring (1) and the ring (2).

Copyright © SECTION 84 - BACKHOE ATTACHMENT BACKHOE BUCKET Move the machine to a level and firm ground. Position the backhoe bucket so that the bucket teeth can be replaced. Place the direction-of-travel lever and gearshift lever in neutral position. Immobilize the machine by means of the parking brake. Stop the engine and remove the starter key.

WARNING Nobody must be in the trajectory of the tooth holder and of the tooth to be removed. During tooth removal, both the tooth holder and the tooth could be unexpectedly projected, thus hitting persons standing in their trajectory or nearby. Projected metal chips could hit persons and cause injury. Remove the tooth holder (2) using a hammer and a chisel. Remove the tooth (1) from the tooth holder (3). Clean the inside of the tooth holder, removing any dirt or rust. Insert a new tooth (1) into the tooth holder (3). Lock the new tooth by installing the tooth holder (2).

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BACKHOE ATTACHMENT HYDRAULIC HANDLING A unit enabling the hydraulic handling of the sideshift carriage which supports the backhoe attachment may be installed on the machine.

CONTROLS Press the backhoe attachment sideshift unlocking switch (1). The switch lamp turns on (ON position). (A) Version with mechanical engines (B) Version with electric engines

For handling, press: - the button (2) side with the symbol to move the backhoe attachment to the left side of the track; - the button (2) side without symbol to move the backhoe attachment to the right side of the track. NOTE: track sides are referred to the travel direction of the machine. Press the backhoe attachment sideshift locking switch (1). The switch lamp turns off (OFF position). IMPORTANT: except when the sideshift carriage is being moved, the switch (1) must always be in the OFF position. Never use the backhoe attachment with the sideshift carriage unlocked.

Copyright © SECTION 84 - BACKHOE ATTACHMENT HYDRAULIC DIAGRAM

A. Backhoe attachment control valve B. Union tee of main load-sensing line from backhoe attachment control valve

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DISASSEMBLY AND ASSEMBLY

1. M14 x 210 hex screw [Tightening torque = 85 ÷ 115 Nm (62.69 ÷ 84.82 lbf·ft)] 2. Washer 3. Plate 4. Pin 5. Snap ring 6. Nut M14 7. Support 8. Shoe 9. Shim 10. Handling cylinder assy 11. M14 x 50 hex screw [Tightening torque = 135 ÷ 183 Nm (99.57 ÷ 134.97 lbf·ft)]

12. Washer 13. Spacer 14. Spacer 15. Snap ring 16. Pin 17. Cylinder support 18. Handling cylinder 19. M8 x 14 hex screw 20. Shim 21. Washer 22. Shoe 23. Shim 24. Fitting 25. M12 x 20 socket head screw 26. Shoe

Copyright © SECTION 84 - BACKHOE ATTACHMENT HANDLING CYLINDER


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NOTES:


Case T-series TLB En

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