Case T-Series TLB en

Copyright
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:
- Operators Manual
- Service Parts Catalogue
SERVICE MANUAL
The Service Manual consists of two volumes:
- 580T - 580ST - 590ST - 695ST
Service Manual for Backhoe loader
- 580T - 580ST - 590ST - 695ST
Service Manual for Engine
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
Copyright
PREVENT ACCIDENTS
The majority of accidents and injuries which occur in the workshop, at the worksite or on the road, are caused
by the failure of some individual to follow simple and fundamental safety rules or precautions. For this reason
most accidents can be prevented by recognizing the real cause and taking the necessary precautions, before
the accident occurs.
Regardless of the care used in design and construction of any type of equipment, there may be conditions
that cannot be completely safeguarded against, without interfering with reasonable accessibility and efficient
operation.
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.
Copyright
BACKHOE LOADER MODELS

The complete range of Backhoe Loader models described in this manual are identified below:
580T
Powershift
580ST
590ST
695ST
Powershuttle
Sideshift stabilizers
Center pivot stabilizers
Rops
2WD
/
/
Cab
4WD
4WS
Pilot control
Mechanical control
Engine Iveco 72 kW - 97 HP model
F4GE9484C*601 (mechanical)
F4HE0484G*J102 (electronic)

F4HE9484C*J102 (electronic)
Engine Iveco 82 kW - 110 HP (4WS) model

Short backhoe dipper
Long backhoe dipper
Copyright
Copyright
INDEX
SECTION 00 - SAFETY RULES
FOREWORD..................................................................................................................................................... 4
SAFETY INSTRUCTIONS ................................................................................................................................ 6
PREVENTION OF FIRE OR EXPLOSIONS..................................................................................................... 8
PREVENTION OF BURNS ............................................................................................................................... 9
PRECAUTIONS FOR WASTE DISPOSAL..................................................................................................... 10
SECTION 01 - MAINTENANCE
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 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
REPAIR TIMES........................................................................................................................................ 335
SPECIAL TOOLS..................................................................................................................................... 336
SECTION 25 - FRONT AXLE

2WD - 2WS FRONT AXLE................................................................................................................................ 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
TROUBLESHOOTING ............................................................................................................................... 57
SPECIAL TOOLS....................................................................................................................................... 61
4WS FRONT AXLE ......................................................................................................................................... 62
Copyright
INDEX
SECTION 27 - REAR AXLE
2WS REAR AXLE (580T - 580ST).................................................................................................................... 3
TROUBLESHOOTING............................................................................................................................... 61
REPAIR TIMES.......................................................................................................................................... 67
SPECIAL TOOLS....................................................................................................................................... 68
2WS REAR AXLE (590ST) ............................................................................................................................. 69
TROUBLESHOOTING............................................................................................................................. 127
REPAIR TIMES........................................................................................................................................ 133
SPECIAL TOOLS..................................................................................................................................... 134
4WS REAR AXLE (695ST) ........................................................................................................................... 135
LUBRICATION AND GREASING ............................................................................................................ 138
REPAIR TIMES........................................................................................................................................ 225
SPECIAL TOOLS..................................................................................................................................... 227
SECTION 33 - BRAKE SYSTEM

PARKING BRAKE............................................................................................................................................. 3
OPERATION................................................................................................................................................ 3
ADJUSTMENT............................................................................................................................................. 4
SERVICE BRAKE ........................................................................................................................................... 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
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
CONTROLS AND OPERATION .............................................................................................................. 130
COMPONENTS ....................................................................................................................................... 131
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
POWER STEERING ....................................................................................................................................... 11
COMPONENTS ......................................................................................................................................... 13
DISASSEMBLY.......................................................................................................................................... 15
ASSEMBLY................................................................................................................................................ 18
SECTION 50 - CAB HEATING AND AIR CONDITIONING

GENERAL.................................................................................................................................................... 3
CAB HEATING.................................................................................................................................................. 5
CONTROLS ................................................................................................................................................. 5
OPERATION................................................................................................................................................ 6
AIR FLOW DIFFUSERS .............................................................................................................................. 7
OVERHAUL ................................................................................................................................................. 9
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
REMOVAL AND INSTALLATION .............................................................................................................. 53
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
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
ALTERNATOR .............................................................................................................................................. 135
OPERATION ............................................................................................................................................ 136
BATTERY...................................................................................................................................................... 138
OPERATION ............................................................................................................................................ 138
REPLACEMENT ...................................................................................................................................... 139
CHARGE AND ELECTROLYTE LEVEL CHECK .................................................................................... 140
CONNECTING A BOOSTER BATTERY ................................................................................................. 141
BATTERY MASTER SWITCH ................................................................................................................. 141
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
Copyright
INDEX
Copyright
580T
580ST
590ST
695ST
Copyright
2
Copyright
SAFETY INSTRUCTIONS
WARNING
This warning symbol points out important messages involving your safety.
Carefully read the safety rules contained herein
and follow advised precautions to avoid potential
hazards and to safeguard your safety and personal
integrity.
In this manual you will find this symbol together
with the following keywords:
WARNING
This symbol warns about the possibility of potential
damages to the machine that can involve the operators safety.
WARNING
With specific warnings about potential dangers for
the operators or other persons integrity directly or
indirectly involved.
The non-compliance with the warnings preceded by
the above-mentioned keywords (WARNING and
DANGER) can cause serious accidents or even the
death of the persons involved.
Moreover, in the present Manual, some instructions
are given with text in italics, preceded by the words
NOTE and CAUTION.
NOTE: it emphasizes and underlines to the operator
the correct technique or correct procedure to follow.
WARNING
This symbol warns about the possibility of potential
damages to the machine that can involve the operators safety.
Copyright
4
FOREWORD
Backhoe loaders 580T - 580ST - 590ST - 695ST
have been designed to perform most earth-moving
operations.
If you use this machine for duties involving the use
of attachments, accessories, or special tools, consult your Dealer to make sure that the adaptations or
modifications carried out are in conformity with the
machines technical specifications and with current
regulations on safety.
Any modifications or adaptations which are not
approved by the manufacturer may invalidate the
machines original conformity with safety requirements.
The machine must be used according to its intended
use, respecting the safety and precautionary rules
and strictly following the operating instructions.
Any functional disorders, especially those affecting
the safety of the machine, should therefore be rectified immediately.
DANGER
A different use of the excavator or of its working
equipment:
- for lifting or transporting persons;
- as a working platform;
- for lifting loads without the attachment being
approved for this purpose;
- for pulling loads;
- is considered unintended use.
Unintended use may cause injury or life-threatening
risks for the operator and for other persons.
The manufacturer/supplier cannot be held responsible for any damage resulting from unintended use.
The risk involved in such misuse lies entirely with
the user.
DANGER
It is absolutely forbidden to tamper with and/or
change the setting of any of the hydraulic system
valves to avoid damaging machine components,
with a consequent risk for personal safety.
The current Operators Manual is the users guide
for correct run-in, use and maintenance of the
machine.
Copyright
Carefully read this Operators Manual and store it in
the cab for quick location and reference.
Instructions concerning safety, operation and maintenance have been developed to permit safe service and repair of this machine without any risk.
In the event of queries or suggestions relevant to
your machine do not hesitate to address to your
Dealer.
Dealers have qualified and trained personnel at disposal as well as Original Spares, means and equipment suitable to carry out all necessary
maintenance.
Any modifications or adaptations which are not approved by the manufacturer may invalidate the machines original conformity with safety requirements.
IMPORTANT: the engine and fuel system on your
machine are designed and built to government
emissions standards. Tampering by dealers, customers, operators and users is strictly prohibited by
law. Failure to comply with this prohibition could
result in government fines, rework charges, invalid
warranty, legal action and possible confiscation of
the machine until rework to original condition is
completed. Engine service and/or repairs must be
carried out by a certified technician only.
NOTE: each machine is supplied complete with a
copy of this Manual. Descriptions and illustrations
provided herein are not binding. The Manufacturer,
provided that the basic characteristics of machine
types described and shown in this Manual remain
the same, reserves the right to change components, parts and accessories supplied without any
commitment to timely update this publication; and
this any time it deems it convenient for improvement purposes or due to commercial or manufacturing requirements. For exact information, please
consult your Dealer or contact the Manufacturers
Branch Offices, who remain at your disposal for further help.
SPARE PARTS
The non-genuine spare parts have not been
checked and authorized by the Manufacturer.
The assembly and/or use of such products may
have negative effects on the machine design features and could impair its operation safety.
The Manufacturer is not liable for any damage
caused by non-genuine spare parts or accessories.
WARRANTY
This machine is under warranty according to the
regulations in force in Your Country and in compliance with the sales agreement drawn up with the
Dealer.
The warranty, however, expires if the operation and
maintenance instruction for this machine and contained in this manual, have not been followed.
Copyright
6
SAFETY INSTRUCTIONS
Carefully read the safety rules contained herein and
follow advised precautions to avoid potential hazards and to safeguard your safety and personal
integrity.
Your safety and that of the people around you
depends on you.
It is essential that you understand this manual for a
correct inspection, lubrication and repair of this
machine.
Read this manual carefully and check that:
- you understand fully the symbols on the controls
and the safety signs used in this manual and on
the machine;
- you understand fully the speed, stability, braking
and steering characteristics of the machine. If you
are in any doubt, consult your Dealer.
The safety messages in this section concern situations which may arise during normal machine operation, servicing and repair. These safety messages
also indicate the different ways of coping with these
situations. Other safety messages are used
throughout the manual to indicate specific dangers.
The information given in this chapter is a summary
of the basic rules to respect at all times and does
not exempt you from observing traffic regulations or
the requirements of insurance companies.
The presence of grease, oil, mud or (in winter) ice
on the steps and access handles can cause accidents. Make sure they are always clean.
When mounting or dismounting from the machine
always face the machine and use the steps and
access handles on the left-hand side of the
machine.
Copyright
Wear close fitting clothing and safety equipment
appropriate for the job:
- safety helmet;
- safety shoes;
- heavy gloves;
- reflective clothing;
- wet weather clothing.
If the environment conditions make it necessary, the
following personal safety equipment should be at
hand:
- respirators (or dustproof masks);
- ear plugs or acoustic ears protections;
- goggles with lateral shield or masks for eyes protection.
Do not wear rings, wristwatches, jewels, unbuttoned
or flapping clothing such as ties, torn clothes,
scarves, open jackets or shirts with open zips which
could get caught into moving parts.
Any functional disorders, especially those affecting
the safety of the machine, should therefore be rectified immediately.
Make sure that you fully understand the symbols of
the safety decals applied on the machine. Make
sure that they are always clean and perfectly legible.
Be prepared for emergencies.
Always keep a first aid kit and a fire extinguisher
close at hand on the machine.
Make sure that the fire extinguisher is serviced in
accordance with the manufacturers instructions.
Copyright
8
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 manufacturers instructions.
Copyright
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.
Copyright
10
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 Earths 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.
Copyright
580T
580ST
590ST
695ST
Copyright
2
Copyright
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.
Copyright
4
Place some wedges under the wheels so as to prevent the machine from moving.
Unauthorized modifications of the machine can
cause serious injuries.
Do not carry out any modification on this machine
without obtaining prior authorization from your
Dealer.
Any modification carried out must be in conformity
with the machines technical specifications and must
conform to current safety regulations.
Do not carry out any welding operation on the
machine without prior authorization from your
Dealer.
Some of the machines components are subject to
type approvals. It is mandatory when replacing
those components to ensure that they are in conformity with regulations.
Hydraulic fluid or grease under pressure which penetrates the skin can cause serious injury.
Take the necessary safety precautions (protective
clothing and face and hand protection) to prevent all
such risks.
In addition, before handling these products, read the
manufacturers specific instructions for their use.
If hydraulic fluid penetrates the skin a doctor must
be called immediately.
When carrying out a welding operation on the
machine, as authorized by the manufacturer and in
accordance with his specifications, disconnect the
electric system by means of the battery master
switch, connect the welding set earth lead to the
component on which the welding is to be carried out
(never connect the ground lead to a hydraulic system component) and disconnect the electric cables
of the motor control unit (in case of electronic
motors).
A burst tyre can cause serious injury.
Regularly check the condition of tyres and always
observe the inflation pressures defined in accordance with the type of tyre and ground conditions.
Copyright
When checking the tyre pressure or during an inflation operation, never stay in front of the tyre but
always keep to the tread side.
Always use an inflation cage when the wheel is
removed from the machine.
Keep all other persons away from the area.
Never weld near a tyre. It is essential to remove the
tyre before any welding operation.
Take the necessary safety measures to protect your
face when using compressed air.
The machines structure is in conformity with the
FOPS and ROPS protection standards.
Any modification (drilling, welding, etc.) may cause
that conformity to be invalidated.
Copyright
6
NOTE:
Copyright
580T
580ST
590ST
695ST
SECTION 02 - TECHNICAL
SPECIFICATIONS
MODELS........................................................................................................................................................... 3
IDENTIFICATION OF MAIN COMPONENTS................................................................................................... 4
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 - 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.
Copyright
MODELS
580T
Powershift
580ST
590ST
695ST
Powershuttle
Stabilizer sideshift
Stabilizer center pivot
Rops
2WD
/
/
Cab
4WD
4WS
Pilot control
Mechanical control
F4GE9484C*601 (mechanical)
F4HE0484G*J102 (electronic)

Engine Iveco 82 kW - 110 HP (4WS) model

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
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
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 lbfft) @ 1250 rpm
Low idle speed at no load ........................................................................................................... 1000 50 rpm
High idle speed at no load (engine not installed) ........................................................................ 2430 50 rpm
High idle speed at no load (engine not installed on the vehicle) ................................................. 2380 60 rpm
Maximum speed at full load ................................................................................................................ 2200 rpm
Air intake ....................................................................................................TAA (turbocharged with aftercooler)
Supply
Type ............................................................................................................................................ direct injection
Injection pump ............................................................................................. BOSCH ROTARY VE 4/12 F1100L
Injection sequence ..................................................................................................................................1-3-4-2
Cold-start device .............................................................................................................grid heater (optional)
Cooling
Pump type ......................................................................................................................................... H2O pump
Pump drive ...........................................................................................................................................belt drive
Temperature switch (opening start) .......................................................................... 81 2 C (177.8 35.6 F)
Copyright
72 kW - 97 HP ENGINE (580ST)
Specifications (EEC 88/195) .................................................................................. 72 kW - 97 HP @ 2200 rpm
Model .................................................................................................................................... F4HE0484G*J102
Type .........................................................................................................................................diesel, electronic
No. of cylinders ................................................................................................................................................ 4
Valves per cylinder ........................................................................................................................................... 4
Bore ............................................................................................................................................. 104 mm (4 in)
Stroke........................................................................................................................................ 132 mm (5.2 in)
Displacement .................................................................................................................. 4485 cm3 (237.69 in3)
Compression ratio.................................................................................................................................... 17.5:1
Maximum torque (EC) ...................................................................................... 453 Nm (334 lbfft) @ 1400 rpm
Low idle speed at no load ........................................................................................................... 1000 50 rpm
High idle speed at no load (engine not installed) ........................................................................ 2430 50 rpm
High idle speed at no load (engine not installed on the vehicle) ................................................. 2380 60 rpm
Maximum speed at full load ................................................................................................................ 2200 rpm
Air intake ....................................................................................................TAA (turbocharged with aftercooler)
Supply
Type ........................................................................................................................high-pressure, common rail
Injection pump............................................................................................................ CP3 high-pressure pump
Control unit................................................................................................................................................EDC7
Injection sequence ..................................................................................................................................1-3-4-2
Cold-start device .............................................................................................................grid heater (optional)
Cooling
Pump type ......................................................................................................................................... H2O pump
Pump drive ...........................................................................................................................................belt drive
Temperature switch (opening start)......................................................................... 81 2 C (177.8 35.6 F)
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 lbfft) @ 1400 rpm
Low idle speed at no load ............................................................................................................ 1000 50 rpm
High idle speed at no load (engine not installed) ......................................................................... 2430 50 rpm
High idle speed at no load (engine not installed on the vehicle) .................................................. 2380 60 rpm
Maximum speed at full load ................................................................................................................. 2200 rpm
Air intake .....................................................................................................TAA (turbocharged with aftercooler)
Supply
Type .........................................................................................................................high-pressure, common rail
Injection pump ............................................................................................................. CP3 high-pressure pump
Control unit.................................................................................................................................................EDC7
Injection sequence ...................................................................................................................................1-3-4-2
Cold-start device ..............................................................................................................grid heater (optional)
Cooling
Pump type .......................................................................................................................................... H2O pump
Pump drive ............................................................................................................................................belt drive
Temperature switch (opening start) .......................................................................... 81 2 C (177.8 35.6 F)
Copyright
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)

4WD/2WS TRANSMISSION - POWERSHIFT (580ST - 590ST)

4WD/4WS TRANSMISSION - POWERSHIFT (695ST)

Model ..................................................................................................................... CARRARO TLB2 MPB 4WS
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
Copyright
11
BRAKES
SERVICE BRAKES
2WS
Type .......................................................................................................wet multi-discs, 4 x axle (2 x half axle)
Braking surface ..................................................................................................................... 1236 cm2 (191 in2)
4WS
Type .......................................................................................................wet multi-discs, 6 x axle (3 x half axle)
Braking surface .................................................................................................................... 1092 cm2 (169 in2)
PARKING BRAKE
Type ....................................................................................................................................... manual, with lever
Maximum lever pull ....................................................................................................................1650 N (371 lbf)
Lever stroke ............................................................................................................................... 21 mm (0.87 in)
Maximum torque - POWERSHUTTLE ...............................................................................2000 Nm (1475 lbfft)
Maximum torque - POWERSHIFT ..................................................................................... 1500 Nm (1106 lbfft)
STEERING
2WS ............................................................................................................................................... 2 wheel steer
4WS ............................................................................................................................................... 4 wheel steer
System pressure .............................................................................................. 170 175 bar (2465 2538 psi)
POWER STEERING
2WS (with variable-flow-rate pump)
Model ......................................................................................................................... EATON P/N 403 -8754-04
Displacement ............................................................................................................. 160 cm3/rev (9.76 in3/rev)
Shock valve adjustment ......................................................................................................... 235 bar (3408 psi)
Load-sensing pressure relief valve adjustment...................................................................... 175 bar (2538 psi)
2WS (with gear pump)
Model ......................................................................................................................... EATON P/N 403 -8754-08
Load-sensing pressure relief valve adjustment............................................................................................... No
4WS
Model ......................................................................................................................... EATON P/N 403 -7754-04
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)
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)
Copyright
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 lbfft)
Rear nuts (2WS) ....................................................................................................................540 Nm (398 lbfft)
Front and rear nuts (4WS) .....................................................................................................700 Nm (516 lbfft)
Copyright
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)
Loader bucket reach
2060 mm (81.10 in)
Wheel base
2175 mm (85.62 in)
Backhoe bucket dimensions
1630 mm (64.17 in)
Rear wheel base - backhoe attachment swing axis
1325 mm (52.16 in)
Machine maximum height (upper part of backhoe attachment boom)
3680 mm (144.88 in)
Stabilizer width
2430 mm (95.66 in)
Cab height
2950 mm (116.14 in)
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)
Loader bucket reach
1975 mm (77.75 in)
Wheel base
2200 mm (86.61 in)
1630 mm (64.17 in)
1325 mm (52.16 in)
Machine maximum height (upper part of backhoe attachment boom)
3650 mm (143.70 in)
Stabilizer width
2480 mm (97.63 in)
Cab height
2900 mm (114.17 in)
Loader bucket width
2400 mm (94.48 in)
Copyright
17
DIMENSIONS - 4WS CENTER PIVOT
Front and rear tyres ...............................................................................................................440/80 R28 IT530

A
7295 mm (287.20 in)
Loader bucket reach
1975 mm (77.75 in)
Wheel base
2200 mm (86.61 in)
3120 mm (122.83 in)
1325 mm (52.16 in)
Machine maximum height (with standard dipper)
3712 mm (146.14 in)
Standard stabilizer width - reversible
2380 mm - 2580 mm
(93.70 in - 101.57 in)
Cab height
2900 mm (114.17 in)
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)
Maximum height of loader bucket pin/pivot
3460 mm (136.22 in)
Maximum dumping height
Digging depth
120 mm (4.72 in)
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
Copyright
19
695ST

A
Maximum height/dimensions
4350 mm (171.26 in)
Maximum height of loader bucket pin/pivot
3490 mm (137.40 in)
Maximum dumping height
2715 mm (106.89 in)
Digging depth
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
Maximum height of loader bucket pin/pivot with lifted forks
4245 mm (167.13 in)
Fork maximum height
3460 mm (136.22 in)
Height of loader bucket pin/pivot of loader bucket with lowered forks
Fork reach when raised
2320 mm (91.34 in)
Fork reach when lowered
3185 mm (125.39 in)
Maximum height of loader bucket pin/pivot with lifted forks
3520 mm (138.58 in)
Fork maximum height
3060 mm (120.47 in)
Height of loader bucket pin/pivot of loader bucket with lowered forks
Fork reach when raised
2195 mm (86.42 in)
Fork reach when lowered
3185 mm (125.39 in)
460 mm (18.11 in)
695ST
460 mm (18.11 in)
Copyright
21
BACKHOE ATTACHMENT PERFORMANCE

580T - 580ST - 590ST
Front tyres ..................................................................................................................................... 12.5/80-18 I3

Rear tyres ..........................................................................................................................................18.4-26 R4
Standard dipper
Telescopic dipper
extended
Maximum digging height
5875 mm (231.30 in)
6790 mm (267.32 in)
Maximum height at full load
3925 mm (154.53 in)
4835 mm (190.35 in)
Maximum digging depth
4370 mm (172.05 in)
5435 mm (213.98 in)
Maximum digging reach with lowered bucket
5230 mm (205.90 in)
6240 mm (245.67 in)
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
Telescopic dipper
extended
6190 mm (243.70 in)
7215 mm (284.05 in)
4250 mm (167.32 in)
5270 mm (207.48 in)
4595 mm (180.90 in)
5810 mm (228.74 in)
5185 mm (204.13 in)
6645 mm (261.61 in)
1065 mm (41.93 in)
1735 mm (68.31 in)
198
195
Bucket digging angle
Copyright
23
695ST CENTER PIVOT

Standard dipper
Telescopic dipper
extended
6190 mm (243.70 in)
7215 mm (284.05 in)
4250 mm (167.32 in)
5270 mm (207.48 in)
4595 mm (180.90 in)
5810 mm (228.74 in)
5185 mm (204.13 in)
6645 mm (261.61 in)
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
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
Wheel reduction gear

(each)
1.3
0.34
15.5
3.41
17
3.74
Differential
11
2.90
Wheel reduction gear

(each)
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)

REAR AXLE (2WS)
Differential 580T-580ST
590ST
REAR AXLE (4WS)

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
14.6
in 3
Copyright
580T
580ST
590ST
695ST
POWERSHUTTLE TRANSMISSION................................................................................................................ 3
CONTROLS ................................................................................................................................................. 9
LUBRICATION........................................................................................................................................... 13
GREASING ................................................................................................................................................ 16
REPAIR TIMES........................................................................................................................................ 148
SPECIAL TOOLS..................................................................................................................................... 149
POWERSHIFT TRANSMISSION.................................................................................................................. 150
CONTROLS ............................................................................................................................................. 161
LUBRICATION......................................................................................................................................... 163
GREASING .............................................................................................................................................. 165
REPAIR TIMES........................................................................................................................................ 335
SPECIAL TOOLS..................................................................................................................................... 336
Copyright
2
Copyright
POWERSHUTTLE TRANSMISSION
This transmission is used on powershuttle backhoe
loader models 580T - 580ST - 590ST.
Copyright
4
2WD/2WS TRANSMISSION - POWERSHUTTLE (580T)
Type (4x4) ................................................................................................. 4 forward and 4 reverse travel gears
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)

Copyright
DIMENSIONS
2WD
Copyright
6
4WD
Copyright
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)
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
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)
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
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
loader attachment control lever).
Copyright
10
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
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.
11
Copyright
12
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
LUBRICATION
2WD
4WD
1. Oil filler tube interface

2. Oil drain plug
3. Breather
13
Copyright
14
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.
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
OIL CHANGE
position.
brake.
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.
15
Copyright
16
GREASING
Tecnolube POLYMER 400 grease
Transmission oil
2WD - 4WD
*: no grease, no oil
Copyright
ONLY 4WD
17
Copyright
18
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 lbfft)]
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
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
19
Copyright
20
Copyright
Only 4WD
21
Copyright
22
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
Remove the oil filter (4) and the O-ring (3).
Unscrew and remove the oil filter (6).
Remove fitting (7).
Remove the spool (8).
23
Copyright
24
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
Assembly
Assemble the plugs (13) and the breather (11).
Assemble valve (10).
Assemble the spring (9).
Assemble the spool (8).
25
Copyright
26
Assemble fitting (7).

Tighten to the prescribed torque of 80 Nm (59 lbfft).
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 lbfft).
Copyright
Assemble the plug (5).
27
Copyright
28
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
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).
29
Copyright
30
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
Lubricate the matching seat with the front half box.
Assemble the oil pump (2).

Check that the mark on the oil pump and on the bell
housing coincide.
31
Copyright
32
TUBES
Disassembly
Drain transmission oil.
Loosen and remove the screws (1) and (2).
Remove the tube (3).
Collect the gaskets (4).
Assembly
Assemble the tube (3) with the gaskets (4).
Screw in and tighten the screws (1) and (2) to the
prescribed torque of 40 Nm (30 lbfft).
Copyright
HYDRAULIC CONTROL VALVE
Disassembly
Disconnect all electric connections.
Drain the transmission oil.
Remove the hydraulic control valve (53).
33
Copyright
34
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
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).
35
Copyright
36
Remove the washer (10).
Copyright
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).
37
Copyright
38
Verify the wear condition of the springs (39), (40)

and (41) and of the pin (42).
Remove the ball (26).
Copyright
Remove the solenoid valve coil (30) and the O-ring

(29).

(27).
Unscrew the solenoid tube (24).
39
Copyright
40
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
Remove the O-ring (19).
(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).
41
Copyright
42
Assembly
Assemble the O-rings (17).
Assemble the solenoid tube (18).

Tighten to the prescribed torque of 25 30 Nm
(18 22 lbfft).

Assemble the solenoid coil (18).
Screw in and tighten the nut (20) to the tightening

torque of 5 7 Nm (3.6 5 lbfft).
Copyright
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 lbfft).

43
Copyright
44

Assemble the O-ring (31) on the plug (32).

(5 7.4 lbfft).
Insert the spring (25).
Insert the ball (26).
Copyright
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).
45
Copyright
46
Position and lubricate the gasket (35).
Assemble the valve cover (34).

torque of 9.8 11.8 Nm (7 8.7 lbfft).
Turn the hydraulic control valve (47).

Assemble the washer (10).
Copyright

Screw in and tighten the plug (6) to the tightening
Assemble the piston (4) and the spring (5).
Push piston (4) downwards and assemble the snap

ring (3).
47
Copyright
48

Assemble the plate (50).


Lubricate the gasket (49).
Copyright
Assemble the hydraulic control valve (53).
torque of 15 24.2 Nm (11 17.9 lbfft).
49
Copyright
50
4WD SOLENOID VALVE
Disassembly
Prior to disassembling the 4WD solenoid valve, disconnect all electric connections.
Remove the solenoid body (2).
Copyright
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.
51
Copyright
52
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 lbfft).
Position the gasket (4).
Copyright
Remove the solenoid body (2).
53
Copyright
54
PARKING HANDBRAKE
Disassembly
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
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).
55
Copyright
56
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 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
Counterdisc number
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
Assemble the counterdisc (12), the brake disc (11)
and the ring (10).
Repeat this operation until the brake disc kit is complete.

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 lbfft).
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 lbfft).
57
Copyright
58
2WD - TRANSMISSION BOX
Disassembly
Remove the snap ring (1).
Copyright
Remove the gearshift control assy (3) and the O-ring
(4).

Remove flange (6).

By means of a lever loosen the cover.
Remove the rear cover (8).
59
Copyright
60
Remove the pins (10) by means of a punch.
Remove the retainers (12).
Copyright
Remove the 2 balls (15).
Loosen and remove the screws (16) and the washers (17).
Remove the springs (18).
Remove the balls (19).
61
Copyright
62
Pull the secondary shaft to the rear so that there is

backlash between the snap ring and the rear housing.
Remove transmission shaft PTO (21) by pushing

lightly on the opposite side.
If necessary, replace the seal ring (22) by cutting it.
Copyright
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).
63
Copyright
64
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).

Do not apply any grease/oil on O-rings.
Apply a thin film of sealant on the edge of the rear

half box.
Copyright
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.

65
Copyright
66

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.

(59 lbfft).
Insert the ball (19) and the spring (18).

Assemble the screw (16) and the washer (17).
(59 lbfft).
Copyright
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.
67
Copyright
68
Grease the balls.

Insert the 2 balls (15).
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 lbfft).
Assemble the retainers (12) on the gearbox pins.
Copyright
Assemble the pins (10) to fasten retainers on the
gearbox pins and the dowel pins (11).

cover (8).
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 lbfft).
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).
69
Copyright
70
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 lbfft).
Copyright
4WD - TRANSMISSION BOX
Disassembly
71
Copyright
72
Loosen and remove flange retaining screw (2).

Use a screwdriver and 2 screws to prevent the
flange rotation.
Copyright
Remove cover (7).
Remove the O-ring (8) from the cover (7).
Remove the seal ring (9) from rear cover (7).

(12).
73
Copyright
74
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
Remove the retainers (20).
Remove the 2 balls (23).
75
Copyright
76
Remove the balls (27).
Pull the secondary shaft to the rear so that there is

backlash between the snap ring and the rear housing.
Copyright
Remove transmission shaft PTO (29) by pushing
lightly on the opposite side.
77
Copyright
78
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
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.
79
Copyright
80

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.

Push the front half box onto the rear one.

Copyright
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.
81
Copyright
82
Screw in the 3 screws (6) fastening the cover to the

front box and tighten them to a tightening torque of
23 Nm (17 lbfft).
Assemble and lubricate the O-ring (4) in the 4WD

flange.
Assemble the 4WD flange (5).
Copyright
Screw in the screw (2).

Use a screwdriver to prevent the flange rotation.
(102.5 lbfft).

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.
83
Copyright
84

(59 lbfft).
Insert the ball (27) and the spring (26).

Assemble the screw (24) and the washer (25).
(59 lbfft).
Assemble the bearing (32) on the transmission

shaft PTO (29).
Copyright
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).
85
Copyright
86
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 lbfft).
Assemble the retainers (20) on the gearbox pins.
Assemble the pins (18) to fasten the retainers on

the gearshift pins.
Copyright
cover (16).
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 lbfft).
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).
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 lbfft).
87
Copyright
88
SHAFTS A, D
Disassembly
Grab the shaft with the (A) pliers and pull out the
shaft assy (D).
Copyright
Shaft (A)
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.
89
Copyright
90
Remove the spacer (4).
Remove the gear (6).
Remove the roller retainer (7).
Remove the thrust washer (8).
Copyright
Remove the pin (9).
Lift and remove the snap ring (11).
Remove the discs (18) and the counterdiscs (17).
91
Copyright
92
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
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.
93
Copyright
94
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
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.
95
Copyright
96
If you are to re-use the clutch discs, observe the

assembly order.

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.
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.
Copyright
97
Forward - reverse gear clutch

Disc number (each side)
Counterdisc number (each side)
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 kit nominal thickness [with 163 kg (359.34 lbs) of load]
Shaft (D)
Remove the bearing (16) from the shaft (D) by
means of a puller.

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
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).
99
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
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.
101
Copyright
102
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
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.
103
Copyright
104
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.

By means of tool 380200197 place the bearing (24)
onto the input shaft until it makes contact with the
thrust washer.
Copyright
Assemble the snap rings and place the spacer in
the protection (tool 380001933).
Place tool 380001933 and the spacer on the shaft.


minutes.

shaft.
Remove tools 380001928 and 380001933.
105
Copyright
106

seal ring.

seal ring.
in the groove.
Copyright
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.
107
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
Shaft (D)
Assemble the bearing (16) on shaft (D) by means of
tool 380200230.

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.
109
Copyright
110
SHAFTS B, C
Disassembly
Remove the shafts (B) and (C).
Copyright
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).
111
Copyright
112
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
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).
113
Copyright
114
Remove the shims (20) and the thrust washer (17).
Remove the pin (19).
Remove the 2nd speed gear (18).
Copyright
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.
115
Copyright
116
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
Support the sleeve on blocks.
Push it down and, at the same time, extract the
detent devices of sleeve and hub.
Remove the balls (32), the blocks (33), the springs

(34) and the hub (35).
Remove the 1st speed gear (37).
117
Copyright
118
Only with 4WD models

Remove the 4WD gear (14).

Copyright
Shaft (B)
Use a puller to remove the inner ring of bearing
(39).
Turn the shaft (41).

119
Copyright
120
Assembly
Shaft (C)
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).

Assemble the 4WD gear (14).

Copyright
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.
121
Copyright
122
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
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).
123
Copyright
124
Assemble the 2nd speed gear (18).
Assemble the pin (19).
Assemble the thrust washer (17) and the shims

(20).

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
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).
125
Copyright
126
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
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.

Assemble the 3rd speed gear (3) and the thrust
washer (2) on the shaft.
127
Copyright
128

Heat the inner ring of the bearing (39) to 80 100 C

(176 212 F).
Assemble the inner ring of the bearing (39) by

Heat the bearing to 80 100 C (176 212 F).
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
Position the assy with care, paying attention that the
ends of the yoke pins are correctly seated.
129
Copyright
130
4WD - E SHAFT
Disassembly
Remove the shaft (E).
Copyright
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.
131
Copyright
132
Remove the 2 O-rings (6) and (9).
Remove the seal rings (8).
Copyright
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 springs (4).
133
Copyright
134
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.
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.

Heat the seal ring (8) to 60 80 C (140 176 F).
Assemble the seal ring on the tool.
Copyright
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.

seal ring.

seal ring.
in the groove.
Insert tool 380200208.

Repeat the previously described operations to
insert the second ring.
Lubricate the seal rings.
135
Copyright
136
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
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.
137
Copyright
138
SPEED CONTROLS
Disassembly
For the disassembly of the two half boxes it is necessary to remove the gearshift control assy.
(3).
Copyright
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).
139
Copyright
140
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
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).
141
Copyright
142
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
Assemble and lubricate the O-ring (3) in the seat of
the cover flange.
Put the gearshift control assy behind the rear cover.
Insert the two pins (11) to lock the 3rd and 4th
speed control yoke (13) and the 1st and 2nd speed
control yoke (14).
143
Copyright
144
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.

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.
Copyright
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.).

replace.
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.

clutch discs.
Damaged converter.
Damaged oil thermostat.
Replace the oil thermostat.
Worn-out oil pump.

clutch discs.
Low oil temperature (high oil

viscosity).

Incorrect oil gradient.
Change oil and filters.
Damaged control valve.

shuttle lever.
Damaged converter.
Damaged oil pump.
Ventilation/Cavitation.
Check the oil level.

Check the oil gradient.

bearings, etc.).

replace.
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.

viscosity).

Overheating.
See overheating.
Damaged hydraulic system.
Repair the hydraulic system.
Copyright
147
FAULT
POSSIBLE CAUSE
The gear remains

engaged.
Damaged/stuck shuttle lever.

shuttle lever.
Damaged clutch assembly.

clutch assembly.
Gearshift lever damaged.
Replace gearshift lever.
Damaged 4WD connection assy.
Hydraulic system fault.
Braking sensor fault.

braking sensors.
Gearshift lever damaged.
Replace the gearshift lever.
Lack of 4WD power

transmission.
Gear fails to engage.
ACTION
Copyright
148
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
Oil pump
Oil pump replacement
20
Replacement of lubrication tube
Replacement of supply tube for solenoid valve of

parking brake
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
Copyright
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.
4WD/2WS TRANSMISSION - POWERSHIFT (580ST - 590ST)
4WD/4WS TRANSMISSION - POWERSHIFT (695ST)

Model ..................................................................................................................... CARRARO TLB2 MPB 4WS
Copyright
151

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

Absorption:........................................................................................................................ 1.68 A [20 C (68 F)]
[20 C (68 F)]
2/4 solenoid valve specifications

Absorption:........................................................................................................................ 1.68 A [20 C (68 F)]
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
DIMENSIONS
2WS
153
Copyright
154
4WS
Copyright
HYDRAULIC DIAGRAM
2WS
155
Copyright
156
REF.
DESCRIPTION
NOTES
Suction filter
Pump
Oil filter relief valve
23 bar (333 psi)
Filter
10 Nm (7.4 lbfft)
Torque converter
Oil cooler
Torque converter relief valve
Pressure regulator for sequential valve
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 lbfft)

36 cm3/rev (2.20 in3/rev)
3.5 5.5 bar (50 80 psi)
Copyright
4WS
157
Copyright
158
REF.
DESCRIPTION
NOTES
Suction filter
Pump
Oil filter relief valve
23 bar (333 psi)
Spin-on filter
10 Nm (7.4 lbfft)
Torque converter
Oil cooler
Torque converter relief valve
Pressure regulator for sequential valve
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 lbfft)

36 cm3/rev (2.20 in3/rev)
3.5 5.5 bar (50 80 psi)
Copyright
159
PORTS
2WS
REF.
DIMENSION
USE
7/8 - 14 UNF
7/8 - 14 UNF
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)
9/16 - 18 UNF
0.3 bar (4.3 psi) = maximum pressure in

neutral position
13.5 16.5 bar (196 239 psi)
9/16 - 18 UNF

neutral position
Oil drain plug
9/16 - 18 UNF
9/16 - 18 UNF
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
7/8 - 14 UNF
7/8 - 14 UNF
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)
9/16 - 18 UNF Forward gear pressure check port

neutral position
13.5 16.5 bar (196 239 psi)
9/16 - 18 UNF Reverse gear pressure check port

neutral position
Oil drain plug
9/16 - 18 UNF Oil pressure delivery to differential lock
9/16 - 18 UNF
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)
Copyright
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.
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
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.
position.
Place the direction-of-travel lever and gearshift
lever in neutral position.
brake.
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
position.
brake.
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
GREASING
Transmission oil
165
Copyright
166
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

17. Plate
20. Washer
Copyright
show your transmission, but the procedure is correct.
A. Loctite 510
B. Loctite 542
C. Loctite 518
D. Loctite 638
167
Copyright
168
Copyright
169
Copyright
170
Only 4WS
Copyright
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
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.
NOTE: this port enables you to check the supply

pressure for reverse gear engagement.
173
Copyright
174
NOTE: this port enables you to check the lubrication pressure.

Remove the revolution sensor (15).
Remove the oil thermostat (16).
Copyright
Assembly
Assemble the revolution sensor (15).
Assemble the oil thermostat (16).

Assemble the plugs (12) and (13).

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).

Assemble fitting (7).

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
Assemble the O-ring (5) on the filter (4).
Insert the filter (4).

Screw in the 2 screws (2) and tighten to the prescribed torque of 23 Nm (17 lbfft).
Assemble the oil drain plug (1).

177
Copyright
178
OIL PUMP
Disassembly
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
Remove the oil pump (2).
WARNING
The O-ring can be damaged.
WARNING
Do not disassemble the pump or its operation may
be compromised.
WARNING
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
Lubricate the matching seat with the front half box.
Assemble the oil pump (2).

Check that the mark on the oil pump and on the bell
housing coincide.
181
Copyright
182
Disassembly
Disconnect cable (12).
Copyright
Disconnect the electric connections.
Loosen all the fittings of the delivery pipes connected with the control valve (2).
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
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).

(18 22 lbfft).
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).

torque of 3 4 Nm (2 3 lbfft).
Copyright
Assemble the gasket (3).
Assemble the control valve (2).

187
Copyright
188
HYDRAULIC SYSTEM LINES
Disassembly
Remove the tube (1) (2nd gear).
Copyright
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
Assembly
Assemble the tube (7) (lubrication) by tightening the
fittings to the tightening torque of 30 Nm (22 lbfft).
Assemble the tube (6) (lubrication) by tightening the

Assemble the tube (5) (4WD) by tightening the fittings to the tightening torque of 30 Nm (22 lbfft).
Assemble the tube (4) (1st gear) by tightening the

191
Copyright
192
Assemble the tube (3) (3rd gear) by tightening the

Assemble the tube (2) (4th gear) by tightening the

Assemble the tube (1) (2nd gear) by tightening the

Copyright
PARKING BRAKE
Disassembly
Remove the oil drain plug (T) and drain the oil from
the transmission.
193
Copyright
194
Unscrew the screw (1).

Loosen and remove the screws (6) and (7).

Remove the brake (8) assembly.
Remove the O-ring (9) from the brake (8).
WARNING
Remove the rings (10), the 5 brake discs (11) and

the 5 counterdiscs (12).
Copyright
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

and each brake disc (11) is flat.
If the brake discs (11) are nearly smooth, replace
them.
If the friction material is damaged or appears
burned, replace it.
damage.
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
Counterdisc number
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
Assemble the counterdisc (12), the brake disc (11)
and the ring (10).
Repeat this operation until the brake disc kit is complete.

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.
Assemble the flange (4) and the O-ring (3).

Lubricate the O-ring (3).
(102.5 lbfft).
197
Copyright
198
Only 4WS
Assemble the hub (19), the washer (18) and the
screw (17).
(102.5 lbfft).
Only 4WS
Assemble the brake disc kit and the brake (8).
Tighten the screws (6) and (7) to a tightening
Copyright
TRANSMISSION BOX
Disassembly
199
Copyright
200

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).
Copyright
WARNING
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).
Copyright
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
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.

Do not lubricate the O-rings.
Copyright
Place the 4 O-rings (15) into their seats with a
buffer.
Assemble the front half box (14) on the rear one.

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 lbfft).
207
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).

(102.5 lbfft).
Copyright
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 lbfft).
Assemble the seal ring (G) by means of tool
380200226.
Assemble O-ring (E).
Assemble the flange (D).
Place the washer (B), screw in and tighten the screw
(A) to the tightening torque of 139 Nm (102.5 lbfft).
Copyright
A, D SHAFTS
Disassembly
Grab the shaft with the (A) pliers and pull out the
shaft assy (D).
211
Copyright
212
Shaft (A)
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
213
Copyright
214
Remove the pin (9).
Lift and remove the snap ring (11).
Copyright
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

spring tension.
Remove the piston (19) by blowing in compressed

air through the delivery hole.
Copyright
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
wear or damage.
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.
219
Copyright
220
2WS forward - reverse gear clutch


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)
Copyright
221
4WS forward gear clutch


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)
means of a puller.

means of a puller.
Copyright
Assembly
Shaft (A)
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).
223
Copyright
224
Insert the snap ring (14).

NOTE: make sure that the snap ring (14) is correctly fitted into its seat.
Copyright
spring tension.
Insert the thrust washer (8).
Insert the roller retainer (7).
225
Copyright
226
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

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.
227
Copyright
228
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.

minutes.
Copyright
shaft.
Remove tools 380200224 and 380200225, the
expander/protector and the spacer from the shaft.

seal ring.

seal ring.
in the groove.
Turn the shaft upside down to carry out the operations described previously.
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.
229
Copyright
230

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.

Copyright
minutes.

shaft.
Remove tools 380001928 and 380001933.
Assemble the end of tool 380001927 with the deep

chamfer onto the shaft and over the seal ring.

seal ring.
in the groove.
231
Copyright
232
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.

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.
Copyright
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.

with compressed air at 6 bar (87 psi) and verify the
actual stroke X with a dial indicator.
Only for 2WS input shaft

ensure a play corresponding to
X = 1.60 2.45 mm (0.06 0.10 in)

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)
233
Copyright
234
Shaft (D)
tool 380200230.

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
SHAFT B
Disassembly
Unscrew and remove the screws (28) and remove
the 4WD oil bulkhead (29).
235
Copyright
236
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

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
Remove the bearing (3) and the gear (4) by means
of a puller.
Remove the bearing (3) and the gear (4).
237
Copyright
238
Remove the roller retainer (7) and the thrust washer

(13).
Remove the pin (24) and the spacer (14).
Copyright
Push the thrust washer (10) slightly.
Remove the thrust washer (10) by means of 2

screwdrivers.
239
Copyright
240

spring tension.
Copyright


241
Copyright
242

wear or damage.
assembly order.

total thickness of the clutch disc kit remains within
the wear limits; otherwise replace the clutch disc kit
(11) with a new one.
with a new one.
with oil.
Copyright
243
2nd gear clutch


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 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

spring tension.
245
Copyright
246
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.
Copyright
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.
247
Copyright
248
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.
Copyright

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.
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.
249
Copyright
250

(19) with compressed air at 6 bar (87 psi) and verify
the actual stroke X with a dial indicator.

The piston stroke (19) must be such to ensure a
play corresponding to:
X = 2.20 3.05 mm (0.09 0.12 in)
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
SHAFT C
Disassembly
Unscrew and remove the screws (V1) to detach the
4WD oil bulkhead (P1).
251
Copyright
252

(61) and tool 380200256.

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

(V2).
Remove tool 380200256 and sleeve (62).
Copyright
Overturn the assembly.

Push the thrust washer (39) downwards.
253
Copyright
254

screwdrivers.
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.
Copyright
spring tension.
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).
255
Copyright
256
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
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 feather (32).
257
Copyright
258
Lower the counterdisc (33) slightly to release the

snap ring (34).

screwdrivers.
Copyright

spring tension.
259
Copyright
260
spring (28).
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
Overturn the shaft (23).
Remove the seal rings (16), (17), (18) and (19) by
cutting them.
261
Copyright
262

(8).

(8).
Remove the feather (22).
Slightly lower the thrust washer (5) to release the

snap ring (4).
Copyright
Remove the thrust washer (5) by means of 2 screwdrivers.
263
Copyright
264

spring tension.
spring (11).
Pull out the piston (13) from its seat by blowing in

compressed air through the delivery hole.
Copyright
Remove the bushing (12) and the piston (13).


wear or damage.
265
Copyright
266

assembly order.

wear limits; otherwise replace the clutch disc kit (B)
with a new one.
Moreover, verify that the counterdiscs (A) are perfectly flat, without scrapes or pittings.
with a new one.
with oil.
Copyright
267
1st gear clutch

2.20 0.05 mm (0.09 0.002 in)
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

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

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

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

spring tension.
269
Copyright
270
Insert the kit (40) and the thrust washer (39) into the
gear (54).
Assemble the snap ring (38) making sure it is correctly seated.

and the snap ring (24) with the relevant O-ring,
respectively in the outer and inner seat of the piston
(26).
Copyright
to protect the seal rings.
271
Copyright
272

into its seat.

spring tension.
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
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).
273
Copyright
274
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
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).
275
Copyright
276
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
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).
277
Copyright
278

to protect the seal rings.
Copyright

into its seat.

spring tension.
279
Copyright
280
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
Assemble the thrust washer (8) and the roller
retainer (7).
Assemble the feather (22), the thrust washer (8)

and the roller retainer (7).
281
Copyright
282
Assemble the seal rings (16), (17), (18) and (19) by

Copyright
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
Check that all gears turn freely on main shaft.

to the 1st gear clutch passage.
Listen for the 1st gear piston to move and to lock
Try to shift the 1st travel gear.
It must not turn on the main shaft.
to the 3rd gear clutch passage.
Listen for the 3rd gear piston to move and to lock

Try to shift the 3rd travel gear.
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.

Copyright
284

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).

(26) with compressed air at 6 bar (87 psi) and verify
the actual stroke X with a dial indicator.

X = 0.5 1.95 mm (0.020 0.077 in)

X = 2.20 3.05 mm (0.09 0.12 in)
Copyright
X = 1.725 2.375 mm (0.068 0.093 in)
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).
285
Copyright
286
E SHAFT
(Only for 2WS)
* = 4WD shaft set
Disassembly
Unscrew and remove the screws to detach the 4WD
oil bulkhead.
Copyright
and tool 380200256.


(V).
287
Copyright
288
Remove the bearings (21) and (1) by means of a

puller.
Overturn the shaft.

Press the belleville washers and remove the snap
ring (2) by means of tool 380200258.
Copyright
Remove the belleville washers (5) and the spacer

(6).
Remove the thrust washer (16) and the disc and

counterdisc kit (15).
289
Copyright
290
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).
Copyright
291

assembly order.

with a new one.
with a new one.
with oil.
4WD clutch
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
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).
293
Copyright
294
Assemble the roller retainer (19) and the spacer

(20).
Copyright
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)
295
Copyright
296
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
Press the belleville washers and fit the snap ring (2)
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.
297
Copyright
298
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.
Copyright
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.
299
Copyright
300
E SHAFT
(Only for 2WS)
* = 4WD shaft set
Disassembly
oil bulkhead.
Copyright
and tool 380200256.


(V).
301
Copyright
302
Remove the bearings (1) and (24) by means of a

puller.
Copyright
Press the belleville washers (5) and remove the
snap ring (2) by means of tool 380200258.

(6).

Remove the bell housing assy from the shaft.
303
Copyright
304

Remove the 4WD disc and counterdisc kit (17).
Copyright
Take out the piston (8) by means of pins (10).
piston (8).
305
Copyright
306

assembly order.

with a new one.
with a new one.
with oil.
4WD clutch
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
Assembly
on the piston (8).
Insert the pins (10) on the clutch piston (8).
holes of the output shaft (12).
307
Copyright
308
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).
Copyright
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



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)

available.
SHIM RANGE
Shims mm
(in)
0.1
(0.004)
0.3
(0.012)
0.5
(0.02)
Copyright

311
Copyright
312
Copyright
Assemble the roller retainer (22) and the spacer
(23).
Assemble the seal rings (25) and (26) by means of

tool 380200224.

313
Copyright
314
In order to check the sealing of the rings, put the

piston chamber under pressure with oil at 10 bar
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

shift the 4WD gear.
Copyright
tool 380200239.
315
Copyright
316
E SHAFT
(Only 4WS)
Disassembly
oil bulkhead.
Copyright

(V).
Remove the seal rings (24), (25) and (26).
317
Copyright
318


Copyright
Press the belleville washers (5) and remove the
snap ring (2) by means of tool 380200258.

(6).
Remove the bell housing (12) from the shaft (17).

319
Copyright
320
Take out the piston (8) by means of pins (10).
piston (8).

assembly order.
Copyright
321

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.
with a new one.
with oil.
4WD clutch
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
on the piston (8).
Insert the pins (10) on the piston (8).
holes of the output shaft (12).
Copyright
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).

Make sure that the disc, counterdisc kit and the piston are correctly seated.


Copyright
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)

available.
SHIM RANGE
Shims mm
(in)
0.1
(0.004)
0.3
(0.012)
0.5
(0.02)
325
Copyright
326

Copyright
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
In order to check the sealing of rings (7) and (9), put

the piston chamber under pressure with oil at 10 bar
stroke is 1.70 1.90 mm (0.067 0.075 in).
1. 4WD oil passage

2. 4WD gear
3. Bearing lubrication
4. Shaft
6. Bearing
329
Copyright
330

shift the 4WD gear.
tool 380200239.
Copyright
331
TROUBLESHOOTING
FAULT
The vehicle does not
move.
POSSIBLE CAUSE
ACTION
Control valve supply problem.

control valves.


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.

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.).

replace.
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.


wiring harness.
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.
Copyright
FAULT
Wheel rotation with lifted

vehicle.
Noise.
Irregular coupling.
POSSIBLE CAUSE
333
ACTION

bearings, etc.).

replace.
Braking force external to transmission:

axle operating problem.
Check and repair the axle.

clutch discs.
Damaged converter.
Damaged oil thermostat.
Replace the oil thermostat.
Worn-out oil pump.

clutch discs.

viscosity).

Incorrect oil gradient.
Change oil and filters.

shuttle lever.
Damaged converter.
Damaged oil pump.
Ventilation/Cavitation.
Check the oil level.

Check the oil gradient.

bearings, etc.).

replace.
Damaged hydraulic control valve.
Replace the control valves.
Damaged converter.

viscosity).

Overheating.
See overheating.

operation fault.
Replace EGM/ECU.
Copyright
334
FAULT
POSSIBLE CAUSE
The gear remains

engaged.
Damaged/stuck shuttle lever.

shuttle lever.
Damaged clutch assembly.

clutch assembly.

operation fault.
Replace EGM/ECU.
Damaged 4WD connection assy.
Hydraulic system fault.
Braking sensor fault.

braking sensors.

operation fault.
Replace EGM/ECU.
Damaged clutch engagement assy.
Replace the clutch engagement assy.
Damaged pressure sensors.

sensors.

operation fault.
Replace EGM/ECU.
Lack of 4WD power

transmission.
Gear fails to engage.
ACTION
Copyright
335
REPAIR TIMES
minutes.
We assume that the transmission assy has already
been removed from the machine.
ASSY
Plugs and filters
OPERATION
TIME (minutes)
Oil filter replacement
Oil temperature sensor replacement
Revolutions sensor replacement
Converter replacement
10
Oil pump replacement
20
Replacement of lubrication and gearshift lines (each)
Control valve replacement
20
Control valve overhauling
40
Solenoid valve replacement (each)
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
SPECIAL TOOLS
PN CNH
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

2WD - 2WS FRONT AXLE ............................................................................................................................... 3
TROUBLESHOOTING................................................................................................................................. 7
4WD - 2WS FRONT AXLE ............................................................................................................................. 10
SPECIAL TOOLS....................................................................................................................................... 61
4WS FRONT AXLE......................................................................................................................................... 62
Copyright
2
Copyright
2WD - 2WS FRONT AXLE

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)

Copyright
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
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.
Copyright
6

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.
position.
brake.
mechanically.
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.
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 lbfft)].
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).
Copyright

(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.

intervals.
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.

wrongly adjusted.
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.

on both tyres.
Overload.

on both tyres.
Incorrect wheel alignment.
Replace the parts and check that the

bearings are in good conditions.
Incorrect axle part installation.
Check the installation.
Overload.

on both tyres.
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.
Copyright
FAULT
Vibrations during travel.
Intermittent noise.
POSSIBLE CAUSE
ACTION
Overload.

on both tyres.
Damaged ring gear.
Replace bevel gear.
Differential box screws loose.
Tighten the screws to torque.
Overload.

on both tyres.
Copyright
10
4WD - 2WS FRONT AXLE

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)
Copyright
11
Oil capacity
Oil type

2. Air breather
4. Oil drain plug
5. Greasing points
Differential
Final drive (each)
Copyright
12
WARNING

WARNING
Drain all oil.
Copyright
shored cavity.
position.
brake.
mechanically.
the 2 front tyres by loosening and removing the relevant fixing nuts (5) [tightening torque = 330 Nm
(243 lbfft)].
Disconnect the cardan joint (1).
Loosen and remove the screws (2) with the relevant washers (3) [tightening torque = 460 540 Nm
(339 398 lbfft)].
Remove the front axle (4).
13
Copyright
14

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 lbfft)

213 263 Nm (157 194 lbfft)
Tie rod ball joint nut, standard
129 160 Nm (95 118 lbfft)
Ball joint nut, HD
162 200 Nm (119 147 lbfft)
Tie rod ball joint nut, standard
255 315 Nm (188 232 lbfft)
Breather
11 14 Nm (8 10 lbfft)
Oil drain plug
54 66 Nm (40 49 lbfft)
Lubrication fitting, king pin
20 30 Nm (15 22 lbfft)
Planet carrier retention screw

King pin screw
21 26 Nm (15.5 19 lbfft)
154 188 Nm (114 139 lbfft)
Differential cover screw
96 118 Nm (71 87 lbfft)
Steering cylinder screw
358 442 Nm (264 326 lbfft)
Steering stop nut
200 244 Nm (148 178 lbfft)
Shaft retaining nut
358 442 Nm (264 326 lbfft)
Ring gear support screw, standard
88 108 Nm (65 80 lbfft)
Ring gear support screw, HD
96 118 Nm (71 87 lbfft)
Gear pin screw
95 105 Nm (70 77 lbfft)
Oil drain plug
72 88 Nm (53 65 lbfft)
Bearing cup screw
96 118 Nm (71 87 lbfft)
Ring nut retainer screw
21 26 Nm (15.5 19 lbfft)
Ring gear screw
96 118 Nm (71 87 lbfft)
Pinion
1.7 2.2 Nm (1.2 1.6 lbfft)
Differential
1.5 2.5 Nm (1.1 1.8 lbfft)
Wheel bearing with seal, standard
8 25 Nm (6 18 lbfft)
Wheel bearing with seal, HD
12 25 Nm (9 18 lbfft)
Standard differential
0 1 Nm (0 0.7 lbfft)
Limited slip differential
1 5 Nm (0.7 4 lbfft)
Copyright
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
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
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
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
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
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 lbfft).
Tighten the ring nut (5) using tool 380000468, to a tightening torque of 358 442 Nm (264 326 lbfft).
Copyright
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 lbfft).
Screw on the plug (1) after oil filling.
27
Copyright
28
SWIVEL HOUSING
Disassembly
Unscrew and remove the tie rod nut (1).
Copyright
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
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
Assemble the top king pin (7).
154 188 Nm (114 139 lbfft).
Assemble the bottom king pin (7).

154 188 Nm (114 139 lbfft).
Assemble the ball joint (2) and the nut (1).
Tighten the nut (1) for 2WD to 129 160 Nm

(95 118 lbfft).
Tighten the nut (1) for 4WD to 162 200 Nm
(119 147 lbfft).
33
Copyright
34
CARDAN JOINT
Disassembly
Remove the 4 snap rings (3).
Copyright
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
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
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
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
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
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).
Copyright
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
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
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.
49
Copyright
50
Make sure that the mounting surfaces of the ring

gear (17) are clean and install the ring gear.
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
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).
51
Copyright
52
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 lbfft).
If the rotating torque is lower than specified, further
tighten the nut and check the rotating torque again.
Copyright
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.

53
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 lbfft) 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 lbfft).
If values vary more than 0.001 Nm (0.0007 lbfft),
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
Make the final adjustments of the ring nuts to align
locking devices and confirm the rolling torque.
Apply the yellow compound on the bevel set in 3
places, 120 apart, on 3 teeth each.
Rotate bevel set enough to see pattern in yellow
compound.
Pattern should be per chart above.
Normal wear will flatten (elongate) the contact pattern.
NOTE: this is a non-adjustable bevel set. If pattern
is significantly different from specifications, then
replace bevel set.
If the original ring gear and pinion gear are being
used, the backlash must be equal to the measurement made during disassembly.
Tighten the screws (26) to the prescribed torque
of 266 Nm (196 lbfft).
Screw in the lock screw (29) which blocks the
ring gear and tighten to a tightening torque of
162 200 Nm (119 147 lbfft).
Apply some sealant.
55
Copyright
56
Assemble the differential carrier (2).

Copyright
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).

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

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
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
Overloaded vehicle.
Damaged vehicle.
Replace the bearings and top up oil.
Contaminated oil.

intervals.
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.

intervals.
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.
Copyright
FAULT
POSSIBLE CAUSE
59
ACTION
Bent or broken axle beam.
Intensive use of the vehicle or

overloaded vehicle.
Axle shaft broken on wheel

side.

wrongly adjusted.

wrongly adjusted.
Overload.

on both tyres.
Overload.

on both tyres.
Overload.

on both tyres.

Wheel vibration and tyre

resistance.

steering.
Excessive noise.
Copyright
60
FAULT
Uneven wear of tyre.
Friction noise.
Intermittent noise.
POSSIBLE CAUSE
ACTION
Overload.

on both tyres.
Incorrect wheel adjustment.
Carry out the adjustment and check

that the bearings are in good
conditions.

Presence of foreign objects.
Discard.
Overload.

on both tyres.
Damaged ring gear.
Replace bevel gear.
Overload.

on both tyres.
Copyright
61
SPECIAL TOOLS
PN CNH
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

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)
Copyright
63
Oil capacity
Oil type
1. Oil level plug

2. Air breather
4. Oil drain plug
5. Greasing points
Differential
Final drive (each)
Copyright
64
WARNING

WARNING
Drain all oil.
Copyright
shored cavity.
position.
brake.
mechanically.
Now it is possible to carry out the disassembly of the 2
front tyres by loosening and removing the relevant fixing nuts (7) [tightening torque = 700 Nm (516 lbfft)].
Disconnect the 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).
65
Copyright
66
NOTES:
Copyright
580T
580ST
590ST
695ST

2WS REAR AXLE (580T - 580ST).................................................................................................................... 3
REPAIR TIMES.......................................................................................................................................... 67
SPECIAL TOOLS....................................................................................................................................... 68
2WS REAR AXLE (590ST) ............................................................................................................................. 69
REPAIR TIMES........................................................................................................................................ 133
SPECIAL TOOLS..................................................................................................................................... 134
4WS REAR AXLE (695ST) ........................................................................................................................... 135
LUBRICATION AND GREASING ............................................................................................................ 138
REPAIR TIMES........................................................................................................................................ 225
SPECIAL TOOLS..................................................................................................................................... 227
Copyright
2
Copyright
2WS REAR AXLE

(580T - 580ST)
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 = 34.8 mm (1.37 in) without seal ring)
FP = 115 138 N
(26 31 lbf)
Ring gear-pinion bearing total preload (1)

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 lbfft)
MT = (MP + 0.58) (MP + 0.87) Nm
[MT = (MP + 0.43) (MP + 0.64) lbfft]
(*) 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)
Copyright

Oil capacity (differential)
Oil type

2. Differential oil drain plug
3. Oil breather
4. Oil drain plug
5. Brake breather
17 litres (3.74 gal)

Copyright
6
WARNING

WARNING
Drain all oil.
Clean the plug (2), screw it and tighten to the prescribed torque of 80 Nm (59 lbfft).
Copyright
shored cavity.
Lower the loader attachment to the ground.
Lower the backhoe attachment to the ground.
brake.
Lower the stabilizers until the rear wheels are
slightly lifted from the ground (they are free from
machine weight).
Fasten the rear axle to a lifting hoist or to a support.
Now it is possible to carry out the disassembly of the
2 rear tyres by loosening and removing the relevant
fixing nuts (9) [tightening torque = 700 Nm (516 lbfft)].
Unscrew and remove the screws (4) with the nuts
(2) and the washers (3) and (5) [tightening torque
= 610 678 Nm (445 500 lbfft)].
Remove the rear axle (1).
Copyright
8

show your axle, but the procedure is correct.
A. Loctite 510
B. Loctite 270
C. Loctite 638
Copyright
GREASE POINTS
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
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
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
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
Assembly
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
Assemble the snap rings (13) until they are seated
against the calibrated disc and using a drift
380200245.
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).
15.3 Nm (11 lbfft).
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
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.

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 lbfft).
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
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).
Remove the bearing cup (11) from the wheel hub

(7).
Copyright
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)
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).

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
Screw in and tighten the ring nut (6) with tool
380200244 at tightening torque of 1000 Nm (738
lbfft).
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
DIFFERENTIAL SUPPORT ASSY
Disassembly
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
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
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

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.
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
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) lbfft]
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;
screw on the ring nuts (5) and (6) with the same
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 lbfft).
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
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
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
Push the yoke (2) downwards using the differential
support as a retainer, then remove the plug (1).

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
Assembly
Assemble the O-rings (11) and (12) onto the piston
(10).
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.
41
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).

support as a retainer.
Screw in the plug (1) by hand.
Copyright
Tighten the plug (1) to the requested torque of 80 Nm
(59 lbfft).
43
Copyright
44
DIFFERENTIAL
Disassembly
If differential bearings must be replaced, remove
the bearing cups (1) and (2).
Copyright
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
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).
47
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
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).
49
Copyright
50
Assemble the ring gear (12), apply some sealant

and tighten the screws (11) to a tightening torque of
165 Nm (122 lbfft).
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
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.
51
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
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.
53
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
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).
55
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
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.
57
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.
range:
FPm = FP0 (FP0 + 10) N
[FPm = FP0 (FP0 + 2.25) lbf]
Copyright
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
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)].
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.
range:
FPm = 115 138 N
[FPm = 25.85 31.02 lbf]
59
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.
WARNING
The measured value MPm should be within the following range:

MPm = 2.0 2.4 Nm
[MPm = 1.47 1.77 lbfft]
Once the prescribed preload value is achieved,

caulk the ring nut (1) using a hammer and a punch.
Copyright
61
TROUBLESHOOTING
FAULT
Wheel vibrations.
Tyre resistance.
Broken axle shaft.

steering.
No differential action; jams

during steering.
POSSIBLE CAUSE
ACTION
Axle faulty.
Overload.

on both tyres.
Axle beam bent.
Axle faulty.
Inspect and repair.
Overload.

on both tyres.
Axle beam bent.
Axle faulty.
Inspect and repair.
Overload.

on both tyres.
Axle beam bent.
Axle faulty.
Inspect and repair.
Overload.

on both tyres.
Copyright
62
FAULT
Excessive noise.
Excessive wear of the tyre.
Friction noise.
POSSIBLE CAUSE
ACTION
Axle faulty.
Inspect and repair.
Overload.

on both tyres.
Check that the structure and the

Axle faulty.
Inspect and repair.
Overload.

on both tyres.
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.
Copyright
FAULT
Outer tip of ring gear tooth is
broken.
POSSIBLE CAUSE
the one expected.
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.
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.

damaged or scored.
ACTION

marks detection.
Gear adjustment wrong (excessive

backlash).
Inner tip of ring gear tooth is

broken.
63

temperature.
Unsuitable lubricant.
Oil level low.
Use proper lubricant, fill up to right

intervals.
Replace bevel gear.
intervals.
Drive pinion teeth pitted.
Extremely intense use.
Replace bevel gear.

intervals.
Machine overloaded.
Damaged vehicle.
Crash load.
Bearings worn or pitted.

intervals.

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.

intervals.
Gasket edge cut or scored.

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.

components.

Splines of planetary gear worn

Intense use.
Replace differential gear assy.
Worn or scored surfaces of

the scraper thrust washer.
Replace axle beam, if necessary.
Lubrication wrong.
Inner diameter of pinion

tapered roller bearing worn
out.
Replace bevel gear.

those with a 0.1 mm (0.004 in)
thickness lower than the new ones.
intervals.
Intense use.
Replace bearing.
Excessive pinion end play.
Unsuitable lubrication.

intervals.
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.
Copyright
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.

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.

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
Copyright
67
REPAIR TIMES
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
SPECIAL TOOLS
PN CNH
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
Copyright
2WS REAR AXLE

(590ST)
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
Mechanical and driven

12 35 bar
(174 508 psi)
0.20 0.35 mm
(0.008 0.014 in)
Pinion bearing preload (*)

FPm = 10.0 12.0 daN

(22.48 26.98 lbf)
Ring gear-pinion bearing total preload (*)

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 lbfft)
MTm = (MPm + 0.55) (MPm + 0.83) Nm
[MTm = (MPm + 0.40) (MPm + 0.61) lbfft]
SERVICE BRAKE
Brake type
Wet disc brake
-20 C 150 C (-4 5.9 F)
55 bar (798 psi)

(0.31 0.002 in)
(0.26 0.004 in)
(0.20 0.002 in)
16 cm 3 (0.98 in3)
Copyright
71

Oil capacity (differential)
Oil type

3. Oil breather
4. Oil drain plug
5. Brake breather

Copyright
72
WARNING

WARNING
Drain all oil.
Copyright
shored cavity.
brake.
machine weight).
the 2 rear tyres by loosening and removing the
relevant fixing nuts (9) [tightening torque = 700 Nm
(516 lbfft)].
(2) and the washers (3) and (5) [tightening torque =
610 678 Nm (445 500 lbfft)].
73
Copyright
74

A. Loctite 510
B. Loctite 270
C. Loctite 638
Copyright
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).
WARNING
Copyright
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
BRAKES
Disassembly
Loosen and remove all screws (1) except for 2 as a

safety measure.
79
Copyright
80

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
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.

adjust kits.
Remove the brake cylinder assy (10).
Remove the brake piston (15) from the brake cylinder (10).
Copyright
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
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.
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
Assemble the belleville washers (9) on the screws
(8) paying attention to orient them correctly.
Assemble the screws (8) and the belleville washers

(9).
15.3 Nm (11 lbfft).
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).
87
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.

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 lbfft).
Copyright
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
Connect the hub (7) to a hoisting tool to remove it.
Collect the bearing (9).
Remove the bearing cup (9) from the wheel hub (7).
Remove the seal ring (10) from the wheel hub (7).
Remove the bearing cup (11) from the wheel hub

(7).
91
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)
Assemble the bearing cup (9) with the buffer
380002222.
Assemble the seal ring (10) on the wheel hub (7)
Use tool 380200254 (T) to assemble the seal ring

(10) onto the wheel hub (7).
Copyright
Assemble the bearing (11) onto wheel flange (8)
with a press.
Place the spacer (12) on the wheel flange (8).

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).
93
Copyright
94
Screw in and tighten the ring nut (6) with tool

380200244 at tightening torque of 1000 Nm (738 lbfft).
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
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.
95
Copyright
96
DIFFERENTIAL SUPPORT ASSY
Disassembly
Copyright
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.
bearings.
97
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
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.
99
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.

in.
FTm = FT0 (FT0 + 10) N
[FTm = FT0 (FT0 + 2.25) lbf]
Copyright
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

splined end.

380200272.
range:
FTm = (FPm + 9.2) (FPm + 13.8) N
[FTm = (FPm + 2.07) (FPm + 3.10) lbf]
(4.69 in)].

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
101
Copyright
102

check the assembly of each component and operate on the ring nuts (5) and (6) of the differential
support:
screw on the ring nuts (5) and (6) by the same
value unchanged;
screw on the ring nuts (5) and (6) with the same
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
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
Movements to correct:
1 -> move the pinion for type X contact adjustment;
2 -> move the pinion for type Z contact adjustment.
Copyright
Once all the adjustment operations have been completed, fit the ring nuts (5) and (6) by tightening the
screws (4).
Tighten the screws (4) to a tightening torque of 10 Nm
(7.4 lbfft).

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).

103
Copyright
104
DIFFERENTIAL LOCKING ASSY
Disassembly
Loosen plug (1) without removing it.
Copyright

Remove tool 380200259.
105
Copyright
106
Remove the springs (4) and (8) and the spacer (9).
Extract the rod assy (3) from the differential support.

Remove the O-rings (12) and (13) from the piston
(11).
Copyright
Assembly
Assemble the O-rings (12) and (13) onto the piston

(11).
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).
107
Copyright
108
Insert the springs (4) and (8) and the spacer (9).
Screw in and tighten the plug (1) to the prescribed

Assemble the bushing (6).
Insert tool 380200259 (T1).
Copyright
Assemble the snap ring (5) with tool 380200260
(T2).
Remove tools 380200259 (T1) and 380200260
(T2).

Screw in the plug (1) by hand.
Tighten the plug (1) to the prescribed torque of 30 Nm

(22 lbfft).
109
Copyright
110
DIFFERENTIAL
Disassembly
Copyright
If necessary, replace the differential bearings.
Remove the bearing cups (3) and (4).
Take out the cover (7) and collect the anti-rotation

pin (8) and the ring (9).
111
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
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).
113
Copyright
114
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
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).

ring (17).
Insert pin (13).
Orient the pin (13) with the flat side upwards.

ring (15) and insert the pin (13) and make sure to
align the pin hole with that of the differential box
(24).
115
Copyright
116
Insert the pins (12).

Screw in and tighten the plugs (11) to the prescribed torque of 25 Nm (18.4 lbfft).
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
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 lbfft).
117
Copyright
118
PINION ASSY
Disassembly
WARNING
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
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).

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.
119
Copyright
120

means of a puller.
Check the conditions of all pinion parts.

replaced during assembly.
Copyright
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).
121
Copyright
122

with a depth gauge.
X = (A + C) - B mm (in)
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
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).
123
Copyright
124
Assemble bearing (7) on pinion shaft, using buffer

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.
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.
range:
FPm = FP0 (FP0 + 10) N
[FPm = FP0 (FP0 + 2.25) lbf]
Copyright
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
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.

(4.69 in)].
range:
FPm = 33.3 40 N
(FPm = 7.49 8.99 lbf)
WARNING
Values for new bearings.
range:
FPm = 100 120 N
(FPm = 22.48 2.02 lbf)
125
Copyright
126
If the bearings are new, measure the rolling torque

MPm of the pinion shaft bearings with a torque
meter and the wrench 380200269.
WARNING
The measured value MPm should be within the following range:

MPm = 1.6 2.4 Nm
(M Pm = 1.18 1.77 lbfft)

caulk the ring nut (1) using a hammer and a punch.
Copyright
127
TROUBLESHOOTING
FAULT
Wheel vibrations.
Tyre resistance.
Broken axle shaft.

steering.
POSSIBLE CAUSE
ACTION
Axle faulty.
Overload.

on both tyres.
Axle beam bent.
Axle faulty.
Inspect and repair.
Overload.

on both tyres.
Axle beam bent.
Axle faulty.
Inspect and repair.
Overload.

on both tyres.
Axle beam bent.
Axle faulty.
Inspect and repair.
Overload.

on both tyres.
Copyright
128
FAULT
POSSIBLE CAUSE
ACTION

during steering.
Excessive noise.
Axle faulty.
Inspect and repair.
Overload.

on both tyres.

Axle faulty.
Inspect and repair.
Overload.

on both tyres.


gear set.
Axle faulty.
Inspect and repair.
Friction noise.
Copyright
FAULT
broken.
POSSIBLE CAUSE
the one expected.
Crash load.
Replace bevel gear.

backlash).

marks detection.
Replace bevel gear.


additives.
and ring gear.
teeth have faded.
Replace bevel gear.
Pinion nut loose.
Pinion nut loose.

damaged or scored.
ACTION

marks detection.

backlash).

broken.
129

temperature.
Oil level low.

intervals.
Replace bevel gear.
intervals.
Replace bevel gear.

intervals.
Machine overloaded.
Damaged vehicle.
Crash load.

intervals.

Normal wear.
Pinion nut loose.
Copyright
130
FAULT
Gaskets leak oil.
POSSIBLE CAUSE
ACTION

temperature.

surface if damaged.

intervals.

flange spline.
Intense use.
Replace the flange.
Pinion nut loose.


break.
(stop line).
Intense use.

gear teeth.

components.


Intense use.

Lubrication wrong.

out.
Replace bevel gear.

intervals.
Intense use.
Replace bearing.

intervals.

flange.

Copyright
FAULT
Intermittent noise.
Constant noise.
POSSIBLE CAUSE
131
ACTION

gear and pinion.

Restore the level.
Change lubricant.
Axle beam bent.

not too loud.

and ring gear.

is increased).

and the ring gear.
Replace the pinion.
Damaged ring gear.
Replace bevel gear.

damaged.
Replace bevel gear.
Worn bearings.
Replace the pinion.
Axle beam bent.
Copyright
132
FAULT
POSSIBLE CAUSE
ACTION

damaged.
Copyright
133
REPAIR TIMES
minutes.
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
SPECIAL TOOLS
PN CNH
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
Copyright
4WS REAR AXLE

(695ST)
135
Copyright
136
Manufacturer
Model
Maximum steering angle
Toe-in
CARRARO
26.32M
21 0-1
A1
2.750/1
6.923/1
19.038/1
Input rotation
clockwise
Dry weight
538 kg
(1186 lb)
Differential type
Limited slip or open
0.15 0.30 mm
(0.006 0.012 in)
Pinion bearing preload (*)

(measured on = 34.8 mm without seal ring)
FP = 92 138 N
(FP = 21 31 lbf)
Ring gear-pinion bearing total preload (*)

(measured on = 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
MP = 1.6 2.4 Nm
(MP = 1.18 1.77 lbfft)
MT = (MP + 0.58) (MP + 0.87) Nm
[MT = (MP + 0.43) (MP + 0.64) lbfft]
Copyright
137
SERVICE BRAKE
Brake type
Brake actuation
Wet disc brake

Hydraulic
-25 C 150 C (-13 5.9 F)
Mineral oil
Standard brake discs

(0.20 0.002 in)
(0.19 0.002 in)
(0.350 0.354 in)
Limited slip brake discs

(0.051 0.001 in)
(0.063 0.001 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
Oil capacity
Oil type

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
WARNING

WARNING
Drain all oil.
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].
Rotate again to bring the hole of the plug (4) to
Clean, screw in and tighten the plug (4).
139
Copyright
140

shored cavity.
brake.
machine weight).
the 2 rear tyres by loosening and removing the
relevant fixing nuts (9) [tightening torque = 700 Nm
(516 lbfft)].
(4) and the washers (3) and (5) [tightening torque
= 830 970 Nm (612 715 lbfft)].
Copyright
B. Loctite 270
C. Loctite 638
141
Copyright
142
Copyright
GREASE POINTS
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
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).
Refill the central body with oil.
Copyright
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).
147
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
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).
149
Copyright
150
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
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).
151
Copyright
152
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
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.

153
Copyright
154
Screw in the ball joints (5) and (10) to the ends of the
rod to the prescribed torque of 300 Nm (221 lbfft).
Screw in the nuts (4) and (11) and the tie rods (3)
and (12) to the ball joints (5) and (10).
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
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
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.
155
Copyright
156
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
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)].
157
Copyright
158
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
REDUCTION GEAR
Disassembly
Unscrew the plug (1) and drain oil from the reduction gear.
Loosen and remove the 2 fixing screws (2).
159
Copyright
160
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
Assemble the washers (7) into the pins of the planetary gear carrier (3).
Install the new O-ring (9) on the wheel hub (10).
Assemble the reduction gear assy on the wheel

hub.
torque of 25 Nm (18.4 lbfft).
Refill the epicyclic reduction gear with oil.

161
Copyright
162
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
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
163
Copyright
164
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
Unscrew and remove the screws (15) and (19) from
the upper (16) and lower (18) king pins.
DANGER
Before removing the king pins (16) and (18), secure
the swivel housing (14) with a rope or a hoist or any
other supporting device to guarantee operators
safety.
Remove the king pins (16) and (18).
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.
165
Copyright
166
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
Assemble the lower (18) and the upper (16) king
pins.
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.
Assemble the bearing (12) in the swivel housing

(14).
Assemble the wheel hub (11) on the swivel housing
(14) and fit the bearing (9).
167
Copyright
168
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

Copyright
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.
169
Copyright
170
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
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.
171
Copyright
172
Position the axle on supports suitable to hold it or

secure the assemblies separately to a lifting device.
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
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

Assemble a new seal ring (3) by means of tool
380002226.
Correctly orient the seal ring (3).
Assemble the new O-ring (9) on the beam (8).
173
Copyright
174
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).

Copyright
Assemble the oil recirculation line (12).

Tighten the nuts (11) to the tightening torque of
60 Nm (44 lbfft).
175
Copyright
176
BRAKES
Disassembly
Remove the beam and the axle shaft.
Copyright
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.
177
Copyright
178
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
Assemble the new O-rings (2) and (3) into the piston (4).
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.
179
Copyright
180
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
Bring the piston (4) to stroke end, using tool
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).
181
Copyright
182
Reassemble the beam with the axle central body.
BRAKE DISC REPLACEMENT

Remove the wheel hub assy from the axle.
Remove the beam.
Copyright
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

place the special tool carefully so as not to damage
the piston.
183
Copyright
184
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
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.
bearings.
185
Copyright
186
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 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
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.
187
Copyright
188
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
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 lbfft).
Screw in the 2 screws M16 x 130 (S) in place (B)
and tighten them to the 80 Nm (59 lbfft) torque.
189
Copyright
190
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
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.

in.
FTm = FT0 (FT0 + 10) N
[FTm = FT0 (FT0 + 2.25) lbf]
splined end.
WARNING
All preloads must be measured without seal ring.
191
Copyright
192

380200237.
range:
FTm = (FPm + 11.1) (FPm + 16.7) N
[FTm = (FPm + 2.5) (FPm + 3.7) lbf]
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.
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.

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.
WARNING
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) lbfft]
where MP is the preload of the pinion bearings.
Copyright
check the assembly of each single component and
operate on the ring nuts of the differential support:
screw on the adjusting ring nuts by the same
value (A) unchanged;
- if the total preload is more than the given range,
unscrew the adjusting ring nuts by the same
value (B) unchanged.
Once all adjustment operations have been performed, assemble the ring nut retainers (9), fastening them with the relevant screws (10).
13 Nm (9 lbfft).
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.
193
Copyright
194
NON-SELF-LOCKING DIFFERENTIAL
Disassembly
Lock the differential with a clamp.
Loosen the screws (1) and remove the ring gear (2).
This operation releases also the two half boxes of
the differential.
Copyright
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.
195
Copyright
196
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.

Place the ring gear (2) on the differential box.
Apply sealant on the screw thread (1).
Copyright
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.
197
Copyright
198
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
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.

Place the ring gear (2) on the differential box.
Apply sealant on the screw thread (1).
199
Copyright
200
PINION
Disassembly
Remove the differential assy.
WARNING
bearings.
Unscrew the ring nut (10) using wrench (T1) and

pinion retainer (T2) 380000020 with 3/4 standard
connection.
Copyright
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.

means of a puller.
201
Copyright
202
Check the conditions of all parts.

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
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.

with a depth gauge.
X = (A + C) - B mm (in)
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
203
Copyright
204
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.

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
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.
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.
range:
FPm = FP0 (FP0 + 10) N
[FPm = FP0 (FP0 + 2.25) lbf]
205
Copyright
206
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.

(4.50 in)].
range:
FPm = 31 46 N
[FPm = 6.97 10.34 lbf]
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.
WARNING
Copyright
The measured value MP should be within this
range:
MP = 1.6 2.4 Nm
[MP = 1.18 1.77 lbfft]

caulk the ring nut (10) using a hammer and a
punch.
Assemble the differential assy (3).
207
Copyright
208
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
Check that the difference between the measurements at the ends of the wheel hub diameters is
within the required tolerance range.
The nominal toe-in (A) value is referred to the external diameter of the wheel hubs flange, therefore the
measured toe-in value (M) at the bar ends must be
related to the ratio between length of the bar and
flange diameter:
nominal toe-in = A1
measured toe-in = M3
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 lbfft) 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).
Check that the locks on the opposite sides are both

in contact with the axle beam.
Copyright
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
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 lbfft).
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
Screw in and tighten the nut (2) to a tightening
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 lbfft).
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

Check the correct place of the seal ring (11) according to the axle type.
Copyright
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

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.
Copyright
219
TROUBLESHOOTING
FAULT
Wheel vibrations.
Tyre resistance.
Broken axle shaft.

steering.

during steering.
POSSIBLE CAUSE
ACTION
Axle faulty.
Overload.

on both tyres.
Axle beam bent.
Axle faulty.
Inspect and repair.
Overload.

on both tyres.
Axle beam bent.
Axle faulty.
Inspect and repair.
Overload.

on both tyres.
Axle beam bent.
Axle faulty.
Inspect and repair.
Overload.

on both tyres.
Copyright
220
FAULT
Excessive noise.
Friction noise.
POSSIBLE CAUSE
ACTION
Axle faulty.
Inspect and repair.
Overload.

on both tyres.

Axle faulty.
Inspect and repair.
Overload.

on both tyres.


gear set.
Axle faulty.
Inspect and repair.
Copyright
FAULT
broken.
POSSIBLE CAUSE
the one expected.
backlash).
Pinion nut loose.

broken.
Replace bevel gear.

marks detection.
Replace bevel gear.

backlash).

marks detection.
Replace bevel gear.


additives.
and ring gear.
teeth have faded.
ACTION
Crash load.
Pinion nut loose.

damaged or scored.
221

temperature.
Oil level low.

intervals.
Replace bevel gear.
intervals.
Replace bevel gear.

intervals.
Machine overloaded.
Damaged vehicle.
Crash load.

intervals.

Normal wear.
Pinion nut loose.
Copyright
222
FAULT
Gaskets leak oil.
POSSIBLE CAUSE
ACTION

temperature.

surface if damaged.

intervals.

flange spline.
Intense use.
Replace the flange.
Pinion nut loose.


break.
(stop line).
Intense use.

gear teeth.

components.


Intense use.

Lubrication wrong.

out.

intervals.
Intense use.
Replace bearing.

intervals.
Replace bevel gear.
Copyright
FAULT
POSSIBLE CAUSE
223
ACTION

flange.


gear and pinion.

Restore the level.
Change lubricant.
Axle beam bent.

not too loud.

and ring gear.

is increased).

and the ring gear.
Replace the pinion.
Damaged ring gear.
Replace bevel gear.

damaged.
Replace bevel gear.
Worn bearings.
Replace the pinion.
Axle beam bent.
Intermittent noise.
Constant noise.
Copyright
224
FAULT
POSSIBLE CAUSE
ACTION

damaged.
Copyright
225
REPAIR TIMES
minutes.
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)
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
Copyright
227
SPECIAL TOOLS
PN CNH
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

PARKING BRAKE............................................................................................................................................. 3
OPERATION................................................................................................................................................ 3
ADJUSTMENT............................................................................................................................................. 4
SERVICE BRAKE ........................................................................................................................................... 14
OPERATION.............................................................................................................................................. 14
Copyright
2
Copyright
PARKING BRAKE
This device allows the immobilization of the
machine each time it must be parked or stopped to
carry out maintenance work.
Type ....................................................................................................................................... manual, with lever
Maximum lever pull ....................................................................................................................1650 N (371 lbf)
Lever stroke ............................................................................................................................... 21 mm (0.87 in)
Maximum torque - Powershuttle ..........................................................................................2000 Nm (450 lbfft)
Maximum torque - Powershift ..............................................................................................1500 Nm (337 lbfft)
OPERATION
The parking brake essentially consists of:
- manual control lever;
- transmission brake.
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
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
Copyright
6
DISASSEMBLY
Loosen the screw (1).
Remove the O-ring (3) and the flange (4).
Loosen the screws (5).
Copyright
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 brake discs (16).
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
Remove the O-ring (9) from the piston (10).
Remove the belleville washers (8) from the brake

cover (6).
INSPECTION
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.
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
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).
11
Copyright
12
Assemble the brake discs (16).
Assemble the brake cover assembly.

Assemble the flange (4) and the new O-ring (3).
Copyright
Screw in the screw (1) with the washer (2).

(102 lbfft).
13
Copyright
14
SERVICE BRAKE
During operation, the brake system of the machine
can stop the machine at any time.
2WS
Type ........................................................................................................wet multi-discs, 4 x axle (2 x half axle)
4WS
Type ........................................................................................................wet multi-discs, 6 x axle (3 x half axle)
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

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
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

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

CONTROLS AND OPERATION .............................................................................................................. 130
COMPONENTS ....................................................................................................................................... 131
CONTROL LEVER VALVE ...................................................................................................................... 136
PRELIMINARY CHECKS......................................................................................................................... 138
TROUBLESHOOTING (WITH REXROTH CONTROL VALVES).......................................................... 139
SWING ..................................................................................................................................................... 141
HYDRAULIC PUMP ................................................................................................................................. 142
Copyright
HYDRAULIC DIAGRAMS
HYDRAULIC DIAGRAM - 2WS SIDESHIFT MECHANICAL MODELS
WITH FIXED-FLOW-RATE GEAR PUMP
* Alternative diagram for non-reactive steering
Copyright
4
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
WITH FIXED-FLOW-RATE GEAR PUMP - WITHOUT BACKHOE ATTACHMENT SWING CONTROL VALVE
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.

13. Hydraulic fixed-flow-rate gear pump
14. Priority valve
15. Oil cooler
16. Hydraulic tank
17. Air filter
18. Oil filter
20. Return filter
22A.Lock valve
23A.Lock valve
24. Dipper cylinder
24A.Lock valve
25. Bucket cylinder
26. Swing cylinders
27. Diagnostic
28. Boom cylinder
28A.Lock valve
Copyright
WITH VARIABLE-FLOW-RATE PISTON PUMP
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.

13. Hydraulic variable-flow-rate piston pump
14. Priority valve
15. Oil cooler
16. Hydraulic tank
17. Air filter
18. Oil filter
20. Return filter
22A.Lock valve
23A.Lock valve
24. Dipper cylinder
24A.Lock valve
25. Bucket cylinder
26. Swing cylinders
27. Diagnostic
28. Boom cylinder
28A.Lock valve
31. Bidirectional auxiliary attachment (optional)
Copyright
HYDRAULIC DIAGRAM - 2WS SIDESHIFT PILOT MODELS
WITH FIXED-FLOW-RATE GEAR PUMP
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)
13. Hydraulic fixed-flow-rate piston pump
14. Priority valve
15. Oil cooler
16. Hydraulic tank
17. Air filter
18. Oil filter
20. Return filter
22A.Lock valve
23A.Lock valve
24. Dipper cylinder
24A.Lock valve
25. Bucket cylinder
26. Swing cylinders
28. Boom cylinder
28A.Lock valve
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
WITH VARIABLE-FLOW-RATE PISTON PUMP
11
Copyright
12
1. Front axle steering cylinder

2. Power steering
3A. Lock valve
4. Dipper cylinders
4A. Lock valve
5. Boom cylinders
5A. Lock valve
14. Priority valve
15. Oil cooler
16. Hydraulic tank
17. Air filter
18. Oil filter
20. Return filter
22A.Lock valve
23A.Lock valve
24. Dipper cylinder
24A.Lock valve
25. Bucket cylinder
26. Swing cylinders
28. Boom cylinder
28A.Lock valve
35A.Left hydraulic control lever - boom - dipper
36A.Right hydraulic control lever - boom - dipper
36B.Right hydraulic control lever - swing
Copyright
HYDRAULIC DIAGRAM - 4WS SIDESHIFT MECHANICAL MODELS
13
Copyright
14
1.

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.

15. Hydraulic variable-flow-rate pump
16. Priority valve
17. Oil cooler
18. Hydraulic tank
19. Air filter
20. Oil filter
21. Return filter
26A.Lock valve
27A.Lock valve
28. Dipper cylinder
28A.Lock valve
29. Bucket cylinder
30. Swing cylinders
32. Boom cylinder
32A.Lock valve
33. Telescopic dipper cylinder (optional)
Copyright
HYDRAULIC DIAGRAM - 4WS SIDESHIFT PILOT MODELS
15
Copyright
16
1.

2. 4WS steering control valve

3. Rear axle steering cylinder
4. Power steering
5A. Lock valve
6. Dipper cylinders
6A. Lock valve
7. Boom cylinders
7A. Lock valve
16. Priority valve
17. Oil cooler
18. Hydraulic tank
19. Air filter
20. Oil filter
21. Return filter
25A.Lock valve
26A.Lock valve
27. Dipper cylinder
27A.Lock valve
28. Bucket cylinder
29. Swing cylinders
31. Boom cylinder
31A.Lock valve
32. Telescopic dipper cylinder (optional)
35A.Boom or dipper left hydraulic control lever
36A.Boom or dipper right hydraulic control lever
36B.Hydraulic control lever right-bucket
Copyright
HYDRAULIC DIAGRAM - 4WS CENTER PIVOT PILOT MODELS
17
Copyright
18
1.


3. Rear axle steering cylinder
4. Power steering
5A. Lock valve
6. Dipper cylinders
6A. Lock valve
7. Boom cylinders
7A. Lock valve
16. Priority valve
17. Oil cooler
18. Hydraulic tank
19. Air filter
20. Oil filter
21. Return filter
25A.Lock valve
26A.Lock valve
27. Dipper cylinder
27A.Lock valve
28. Bucket cylinder
29. Swing cylinders
31. Boom cylinder
31A.Lock valve
35A.Boom or dipper left hydraulic control lever
36A.Boom or dipper right hydraulic control lever
36B.Hydraulic control lever right-bucket
Copyright
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.
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)
Copyright
20
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/s) (cSt)
permitted
max 750 mm2/s (29.53 in/s) (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/s) (cSt)
permitted
max 750 mm2/s (29.53 in/s) (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
Tightening torques
Hydraulic diagram
21
Copyright
22
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.
Copyright
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

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.

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
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 valves 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.
25
Copyright
26
Rear pump disassembly

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
Inspect the wear track cut by the gears in pump
body. The body can be reused if the track is bright
and polished and does not exceed 0.08 0.076 mm
(0.0031 0.0029 in) in depth.
Examine bearing block faces for scoring and flatness, paying particular attention to the face which
abuts the gears.
Examine bearing block bushes for scoring.
Examine pump gears for scored or worn side faces,
journals and damaged teeth.
If pump block, gears or bearing blocks are worn and
require replacement the pump assembly must be
replaced.
Re-assemble using the disassembly procedure in
reverse order and observe the following warnings:
- ensure that all parts are perfectly clean and lubricate bushes and gears with clean hydraulic fluid;
- replace all seals and O-rings;
- install the bearing blocks into the same positions
from which they were removed, using the identification letters written during disassembly;
- ensure plastic back-up seals are correctly positioned in the rubber seal.
27
Copyright
28
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
Assemble the inner seal, (30), with the spring and
the lip facing the pump.
Install the outer seal ring (31), with the spring and
the lip facing outwards and refit the snap ring (30).
Coat the rings with high melting point grease.
NOTE: ensure seal rings are fitted back to back.
NOTE: if the seal ring recess has been scored during seal removal, coat the outside diameter of the
seal ring with flexible gasket sealant to prevent
leakage.
29
Copyright
30
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.
Pump 72 kW - 97 HP (580ST)
Displacement ............................................................................................................... 71 cm3/rev (4.33 in3/rev)
Pump 82 kW - 110 HP (590ST - 695ST)
Displacement ............................................................................................................... 75 cm3/rev (4.57 in3/rev)
Copyright
COMPONENTS
31
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
Disassembly
Remove the load-sensing control valve (29) by
removing the 4 screws (30).
Remove and discard the 4 O-rings (28).

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.
33
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).

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
Orient the pump body (3) with the flange upwards.
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).
35
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
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.
37
Copyright
38
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 spools (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
Carefully inspect each surface of the swash plate
(14) for wear. All swash plate surfaces should be
smooth.
Inspect the swash plates running surface for damage and brass transfer.
Excessive transfer may indicate that the pistons
should be replaced.
Finally, check the swash plate pin for scratches.
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.
39
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
Assembly
Coat the cradle bearings (10) with oil and install
them into the pump body (3).
Insert the pins (11) a minimum of 0.5 mm (0.02 in)
below the bearing surface.
If the bearings (10) are reused, reinstall them in
their original position.
Install the bearing (8).
Before replacing the spring (15), coat the contact
surface of the swash plate (14) with oil.
Assemble the swash plate (14), and the piston (16)
and the spring (15) into the pump body (3).
Rotate the piston (16) perpendicularly to the swash
plate (14) and, at the same time, compress the spring
(15) to fit it into the pump body (3).
Liberally lubricate all sides of the piston (16) and its
relevant bore and also the flat face of the swash
plate to prevent premature wear during start-up.
Insert the shaft (9) through the bearing in the body.
Push on the piston to rotate the swash plate in order
to put the shaft in properly.
Lubricate components before assembly.
Install the inner washer (36), the spring (37) and the
outer washer (38) into the cylinder (35). Compress
the spring enough to insert the ring (39).
WARNING
Compressing the spring (37) requires about
350 400 N (79 90 lbf).
Use a press sufficient to maintain this force.
Ensure that the spring is secure before attempting
to assemble the ring (39).
Release the pressure slowly after the ring (39) has
been installed.
Turn the cylinder over and assemble the pins (34)
and the ball guide (33) into the cylinder (35).
Assemble the pistons (31) on the piston disc (32).
Install the piston/disc assy into the cylinder (35).
Ensure the concave surface of the disc seats correctly in the ball guide. If reusing the pistons, install
them to the original cylinder bores.
Lubricate the pistons (31), the piston disc (32) and
the ball guide (33) before assembly.
IMPORTANT: make sure to install the piston disc
(32) so that it mates correctly with the articulation
(33), the concave side of the disc against the convex side of the ball guide.
41
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).
Copyright
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.
43
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
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
13. Oil cooler by-pass valve
45
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

14. Solenoid valve for piloting backhoe control

valve
8. Backhoe hammer control valve
15. Hydraulic control lever

16. Accumulator
Copyright
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
47
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
Copyright
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
Copyright
50
Load sensing flow sharing - One spool operating

Pump pressure
Trapped oil
Return to oil tank
2. Load sense line
4. Spool
Copyright
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
Copyright
52
Load sensing flow sharing - Two spools operating

1st spool operating pressure
Trapped oil
2nd spool operating pressure
Return to oil tank
2. Load sense line
4. Spool
Copyright
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
53
Copyright
54
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
4. 4x1 bucket relief valve - 240 bar (3481 psi)
5. Inlet spool
Copyright
CONTROL VALVE REMOVAL FROM MACHINE
shored cavity.
brake.
Lower the stabilizers to the ground.
On hydraulically controlled machines, turn the key
to ON and release the pressure by moving the
hydraulic control levers in all directions.
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.
55
Copyright
56
DISASSEMBLY
Loosen and remove the 3 nuts (1).
[Tightening torque = 27 2 Nm (19.91 1.47 lbfft)]
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
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).
57
Copyright
58
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
E. Swing section
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)
Copyright
59
With piston pump (with variable flow rate)
1. End cover
2. Inlet section
C. Dipper section
D. Bucket section
E. Swing section
F. Boom section

(4496 psi)
Copyright
60

shored cavity.
Lower the loader attachment and the backhoe
attachment to the ground.
brake.
Identify the position of all hoses to be disconnected
and tag them.
Disconnect the hoses and plug their ends.
Disconnect the manual control levers.
machine.
reverse order.
Copyright
[Tightening torque = 27.2 Nm (20.06 lbfft)]

(5), (6), (7), (8), (9) and (10) and the inlet section
(11).
valve.
Inlet section disassembly

Remove the flow balancer valve (13).
[Tightening torque = 100 Nm (73.76 lbfft)]
Remove the load-sensing valve (14).
Remove the pressure relief valve (15).
Unscrew and remove the plugs (16) and (17).
[Tightening torque = 20 Nm (15 lbfft)]
61
Copyright
62
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);

Remove the check valves (21).

- extract the spring (27) with the relevant spring

guides (26);

- keep the seal (29).
Remove the pressure relief valves (37).

Remove the spool:

- loosen and remove the screws (23);
- remove the cover (24) and the seal (28);
- loosen and remove the yoke (30) with the protection (31);
- remove the flange (33) with the relevant seal
(34);
- keep the seal (35);
- extract the spool (36).
Copyright
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.
63
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)

C. Dipper section
D. Bucket section
E. Swing section
F. Boom section
H. Auxiliary section
1. End cover
2. Inlet section
4. Backhoe bucket relief valve (rod side) - 260 bar

(3771 psi)
5. Backhoe bucket relief valve (piston side) 220 bar (3191 psi)
(4496 psi)
10. Auxiliary section relief valves - 220 bar (3191 psi)
12. Load-sensing relief valve - 205 bar (2973 psi)
Copyright
65
With piston pump (with variable flow rate)

C. Dipper section
D. Bucket section
E. Swing section
F. Boom section
H. Auxiliary section
1. End cover
2. Inlet section
4. Backhoe bucket relief valve (rod side) - 260 bar

(3771 psi)
5. Backhoe bucket relief valve (piston side) 220 bar (3191 psi)
(4496 psi)
10. Auxiliary section relief valves - 220 bar (3191 psi)
Copyright
66

shored cavity.
Lower the loader attachment and the backhoe
attachment to the ground.
brake.
Identify the position of all hoses to be disconnected
and tag them.
Disconnect the hoses and plug their ends.
Disconnect the manual control levers.
machine.
reverse order.
Copyright
[Tightening torque = 27.2 Nm (20.06 lbfft)]

(5), (6), (7), (8), (9), (10) and (11) and the inlet section (12).
valve.
Inlet section disassembly

Remove the load-sensing valve (14).
Unscrew and remove the plugs (16) and (17).
67
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).
Remove the spool:

- remove the cover (27);
- if necessary, replace the O-ring (28);

- remove the spring (29) and the relevant spring
guide (30);
- 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
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
69
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
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
High pressure oil

Exhaust oil
Reduced pressure oil
Copyright
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
71
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
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
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
73
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
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.
75
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
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.
77
Copyright
78
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
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.
79
Copyright
80
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.
Copyright
81
ACCUMULATOR GLIDE RIDE PARKER

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.
Copyright
82
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 accumulators
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.
Copyright
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.

Slacken the bleed valve (B) to release pressure in

the UCA.

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.
the UCA.
Unscrew the UCA from the adapter.
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.

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.
Copyright
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
Copyright
87
HYDRAULIC CYLINDERS
1. Loader attachment boom 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
1. Stroke
Copyright
LOADER ATTACHMENT BOOM CYLINDER REMOVAL
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).
89
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
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.
91
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.

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
LOADER BUCKET CYLINDER
2WS
1. Stroke
4WS
1. Stroke
93
Copyright
94
LOADER BUCKET CYLINDER REMOVAL

Place the bucket firmly on the ground.
positions.
Support the cylinder using a sling or a suitable
hoist.
Support the link rods.

Use a hammer to extract the rod pin (3).

Hammer to slide out the pin (6).
Remove the loader bucket cylinder.
Copyright
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
WARNING
Cylinder weight: 32.5 kg (71.65 lb).
95
Copyright
96
Support the cylinder rod (2) and use the wrench

380000722 to loosen the cylinder head (6).

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).

Only if necessary:
ring (5), the back-up ring (8) with the O-ring (9)
from the cylinder head (6);
ring (12) from the piston (10).
Copyright
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

positions.
97
Copyright
98

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
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
99
Copyright
100
BACKHOE BOOM CYLINDER
1. Stroke
590ST - 695ST
BACKHOE ATTACHMENT BOOM CYLINDER

REMOVAL
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
Disconnect the hoses (T).
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.
101
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).
Copyright
Use wrench 380000724 to loosen the cylinder
head (9).

Remove the cylinder rod (3) and the cylinder
head (9).

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).
103
Copyright
104
BACKHOE ATTACHMENT DIPPER CYLINDER
1. Stroke
590ST - 695ST
BACKHOE ATTACHMENT DIPPER CYLINDER

REMOVAL
Support the backhoe attachment elements for cylinder removal using a suitable support.
WARNING
580T - 580ST
Copyright
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).

Remove the snap rings (5) and the spacers (6).

Slide out the rod pin (7) with an hammer.
Remove the backhoe dipper cylinder.
105
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
Copyright
Loosen the cylinder head (9).

(9).

Only if necessary:
(10) with the O-ring (11) from the cylinder head
(9);
107
Copyright
108
BACKHOE BUCKET CYLINDER
1. Stroke
580T - 580ST
BACKHOE BUCKET CYLINDER REMOVAL

WARNING
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
Disconnect the hoses (T).
Remove the backhoe bucket.
109
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 (590ST - 695ST): 67 kg (147.71 lb).
Copyright

(9).
Loosen and remove the screw (15). Extract the piston (14) and the cylinder head (9) from the cylinder
rod (3).
Only if necessary:
(10) with the O-ring from the cylinder head (9);
111
Copyright
112
TELESCOPIC CYLINDER
1.
Stroke
580T - 580ST
590ST - 695ST
Copyright
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 (590ST - 695ST): 41.9 kg (92.37 lb).
113
Copyright
114


(7).

Only if necessary:
ring (4), the guide bush (5) and the O-ring (9) with
the back-up ring (8) from the cylinder head (7);
Copyright
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.
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.
115
Copyright
116
Stop the engine.

Release possible residual pressure by moving the
control levers of the stabilizers.
Disconnect all hoses.
Remove the snap ring (4) and the shim (5).
Hammer to slide out the pin (6).
Remove the stabilizer cylinder.
Copyright
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
117
Copyright
118
Replace the cylinder rod (1).

Use wrench 380000726 to loosen the cylinder head
(7).

(7).

Only if necessary:
Copyright
STABILIZER CYLINDER - SIDESHIFT
1. Stroke
STABILIZER CYLINDER REMOVAL - SIDESHIFT


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.
119
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
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
Lift and place the cylinder on a workbench and
secure it to a vice.
121
Copyright
122

Unscrew and remove the safety screw (6). Use
wrench 380000721 to loosen the cylinder head (7).

(7).

Only if necessary:
- remove the wiper ring (2), the seal rings (3), the
Copyright
SWING CYLINDER
1. Stroke
SWING CYLINDER REMOVAL

Support the backhoe attachment elements for cylinder removal using a suitable stand and a hoist.
WARNING
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.
123
Copyright
124
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
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.
125
Copyright
126
Use the wrench 380000725 to loosen the king pin

(10).
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:
(12) with the O-ring (11) from the king pin (10).
ring (14) from the piston (15).
Copyright
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.
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).
127
Copyright
128
SPECIAL TOOLS
PN CNH
DESCRIPTION
380000721
Wrench
380000722
Wrench
380000724
Wrench
APPLICATION
Telescopic dipper cylinder head
Stabilizer cylinder head (sideshift)
Loader bucket cylinder head
Backhoe boom cylinder head
Backhoe dipper cylinder head
Backhoe bucket cylinder head
380000725
Wrench
Swing cylinder head

Loader cylinder head
380000726
Wrench
Stabilizer cylinder head (center pivot)
Copyright
129
HYDRAULIC CONTROL LEVERS

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 lbfft)
Control block retaining screw
30 Nm (22 lbfft)
Control block cardan joint
50 Nm (37 lbfft)
Control block nut
40 Nm (30 lbfft)
Lower body screw
50 Nm (37 lbfft)
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
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
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
131
Copyright
132
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
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).
133
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
- Remove the screws (V1) and take out control
lever from the column.

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).
Assembly
Proceed in reverse order.
Follow the marks made during disassembly and tighten
the nut (4) to a torque of 36 44 Nm (26 32 lbfft).
135
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
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 shim (3) from the upper body (4).
Extract the rod guide (5) and replace the seal rings
(6) and (7).
Drift the rod (8) out.
Remove the spring guide (9), the spring (10) and
the shims (11).
Extract the spool assembly.
Hold the cover (12) and remove the safety ring
(13).
Remove the spring (14) and the spool (15).
Remove and note the thickness of the shims (16).
Proceed in the same manner for the other rods.
Secure the upper body (4) in a vice.
Loosen and remove the screw (17) using a key and
replace the O-ring (18).
Separate the upper (4) and lower (19) bodies and
replace the seal rings (20) and (21).
Assembly
To reassemble, proceed in the reverse order to that
of removal.
In the case of reassembly without changing the U/J
cam (1), put the same value of shims (3) as those
in place.
After changing the U/J cam (1) adjust the pressure
of the cam on the rods.
Install a 2 mm (0.079 in) shim (3), check that the
recessing of the push-rods is less than 0.2 mm
(0.009 in), modify the shimming to more or less if
required.
Assemble the new seal rings (6), (7) and O-rings
(18), (20) and (21).
Lubricate the moving parts.
Apply brake thread fluid on the threads of the U/J
cam (1) and the screw (17).
Tighten the cam (1) and the screw (17) to a tightening torque of 50 Nm (37 lbfft).
137
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.
Copyright
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.

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 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

power.
The digging control fails to

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.
Examine lift section of backhoe control

valve assembly for wear and scoring.

damaged.
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.

damaged.
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.

damaged.
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.

damaged.
Stabilizer lock valve leaking.
Inspect/overhaul the stabilizer lock

valve.

damaged.
Copyright
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

scoring.

damaged.
The swing fails to slow

down (bearing stop) at
stroke end.
Built-in sliding limiter damaged.

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

scoring.
Cylinder leak (spools in

neutral).
Internal valve leak.
Examine appropriate valve section of

backhoe control valve assembly for
wear or scoring.

damaged.
Load check valve between control

valve sections damaged.
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.

test.
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.

test.
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
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
Copyright
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).
Copyright
4
2WS SIDESHIFT CHASSIS
4WS SIDESHIFT CHASSIS
4WS CENTER PIVOT CHASSIS
Copyright
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
CARDAN SHAFTS
2WS
1. Front axle
2. Front cardan shaft
3. Screw [tightening torque 33 39 Nm (24 29 lbfft)]
4. Bracket
5. Bracket
7. Rear cardan shaft
8. Rear axle
Copyright
8
4WS
1. Front axle
2. Bracket
4. Front cardan shaft
5. Bracket
7. Rear cardan shaft
8. Rear axle
Copyright
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)
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 lbfft)].
IMPORTANT: make sure that all inlets and pipes are
plugged or blanked off to prevent the dirt from entering them.
Copyright
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)
11
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

DESCRIPTION ................................................................................................................................................. 3
POWER STEERING ....................................................................................................................................... 11
COMPONENTS ......................................................................................................................................... 13
DISASSEMBLY.......................................................................................................................................... 15
ASSEMBLY................................................................................................................................................ 18
Copyright
2
Copyright
DESCRIPTION
The steering system has the following features:
- double-acting steering cylinder;
- oil tank in common with the main hydraulic system;
- a hydraulic pump located on the rear part of the
transmission;
- steering (or power steering) control valve located
on the steering wheels column.
The oil is taken from the tank and reaches the
pump.
The front pump flow is directed to the loader and
backhoe attachment control valves.
Thanks to the presence of a flow divider, the rear
pump delivery guarantees priority oil delivery to the
steering system.
The flow divider includes a load-sensing valve and a
steering system pressure relief valve.
According to the machine model, the steering system can be of 2 types:
- 2WS steering system;
- 4WS steering system.
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
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.
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.
Copyright
4WS STEERING SYSTEM
1. Flow divider
6. By-pass valve
2. Power steering
7. Radiator
3. Hydraulic tank
8. Front axle
4. Return manifold
5. Oil filter
10. Rear axle
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
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.
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
2WS
4WS
CRAB
Copyright
POWER STEERING
The power steering consists of a metering and
emergency pump that includes:
- a gearwheel with fixed stator with inner teeth and
a rotor with outer teeth;
- a 4-way rotary control valve consisting of an outer
sleeve and an inner selection rotor;
- a rotor connected to the steering wheel by means
of the steering column, which can be of two types,
fixed or adjustable;
- a cardan shaft which is mechanically tied to the
gearwheel and to the outer sleeve, and allows the
transmissions movement;
- a set of centering springs between the outer
sleeve and the inner rotor.
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
11
Copyright
12
2WS (with variable-flow-rate pump)

Model ........................................................................................................................ EATON P/N 403 -8754-04
2WS (with gear pump)
Model ........................................................................................................................ EATON P/N 403 -8754-08
Load-sensing pressure relief valve adjustment...............................................................................................No
4WS
Model ........................................................................................................................ EATON P/N 403 -7754-04
Copyright
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
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

Remove the cap (2).
Remove the rotor / stator gear (7).

15
Copyright
16
Remove the shaft (9).

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).
Copyright
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
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.

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 units 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
Rotate the spool and sleeve assembly until the pin
is parallel with the ports face.
Install the shaft (9), making sure it is engaged with
pin (17).
To guarantee proper alignment, mark the shaft (see
reference L2).
When marking the shaft, note the relationship
between slotted end and splined end.
Lubricate and install the O-ring (34).
The lubrication will hold the seal in place.
Note the parallel relationship of reference lines L1,
L2, L3 and L4.
Lubricate and install the O-ring (3).
Remove the cap (2).
Screw in the 7 screws (1).

Pretighten the screws to a tightening torque of 17 Nm
(12 lbfft).
Then tighten the screws to a tightening torque of
35 45 Nm (26 33 lbfft) in the sequence shown
in the figure.
Check for proper timing by turning the spool clockwise and feeling pressure in the R port.
21
Copyright
22
NOTES:
Copyright
580T
580ST
590ST
695ST
SECTION 50 - CAB HEATING AND AIR

CONDITIONING
GENERAL.................................................................................................................................................... 3
CAB HEATING.................................................................................................................................................. 5
CONTROLS ................................................................................................................................................. 5
OPERATION................................................................................................................................................ 6
AIR FLOW DIFFUSERS .............................................................................................................................. 7
OVERHAUL ................................................................................................................................................. 9
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
REMOVAL AND INSTALLATION .............................................................................................................. 53
Copyright
2
Copyright
GENERAL
ENGINE RADIATOR COOLANT
Anti-freeze - Akcela Premium .................................................................................................12 litres (2.64 gal)
Water ......................................................................................................................................12 litres (2.64 gal)
System type ........................................................... Pressurized FULL FLOW by-pass with expansion chamber
FAN BELT DEFLECTION
Natural suction ........................................................................................................ 13 19 mm (0.51 0.75 in)
Turbocharged.......................................................................................................... 10 16 mm (0.39 0.63 in)
THERMOSTAT
Opening starts at.......................................................................................................................... 82 C (179 F)
Fully open at ................................................................................................................................ 95 C (203 F)
Radiator cap.............................................................................................................................. 0.90 bar (13 psi)
MOUNTING SCREW TORQUE
Coolant/hot water hose connections ...........................................................................................5 Nm (3.7 lbfft)
Air hose connections...................................................................................................................5 Nm (3.7 lbfft)
Heater housing to floor fastening screws .................................................................................6.2 Nm (4.6 lbfft)
COOLANT
Type .................................................................................................................................................... HFC 134a
Coolant quantity ............................................................................................................................ 1.2 kg (2.6 lb)
COMPRESSOR OIL
Type ......................................................................................................... SP20 (PAG type, viscosity index 100)
Oil change amount................................................................................................................. 135 cm3 (8.24 in3)
CHECK CONDITIONS
Air inlet temperature.................................................................................................................. 37.8 C (100 F)
Rated air inlet humidity ................................................................................................................................ 40%
Evaporation temperature ................................................................................................................. 0 C (32 F)
Overheating ..................................................................................................................................... 5 C (41 F)
Inlet air speed ...............................................................................................1.0 - 2.0 - 3.0 m/s (3.3-6.6-9.9 ft/s)
Condensation temperature .............................................................................. 58 C (136 F) (16 absolute bar)
Undercooling .................................................................................................................................... 2 C (35 F)
Copyright
4
PERFORMANCE
Performance calculated at 1 m/s (3.28 ft) [191.72 m3/h (6769.31 ft3)]
Exchanged heat ................................................................................................. 5.48 kW
4718.28 kcal/h
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)
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)
Copyright
CAB HEATING
The cab is heated by a radiator mounted below the
cab seat, which is supplied hot water from the
engine coolant system.
A blower motor mounted behind the cab radiator is
used to transfer the heat into the cab.
CONTROLS
Heater blower control
The three-speed blower is controlled by means of a
knob (1) on the instrument console, to the right of
the operators seat.
Turn clockwise to the first position for slow speed.
A further clockwise rotation selects medium and
fast speeds.
The blower draws outside air from beneath the cab
floor and blows it into the cab through a filter.
Temperature control
The temperature of the air coming from the radiator
is adjusted by rotating the control knob (2), which
opens or closes the radiator valve, thus increasing
or decreasing the water flow as required.
Turn clockwise to increase the temperature of the
air coming from the heater.
By rotating counterclockwise, the temperature is
decreased.
Copyright
6
OPERATION
CAB AIR FILTER
Before servicing the air filter situated under the
operators seat, switch off the blower and close all
windows and one door.
Forcibly close the other door.
The resulting back pressure will dislodge loose dirt
from the underside of the filters.
To remove the filter (1), release the retaining straps
(2) and remove the filter element.
Ensure the element, and sealing faces are not damaged on removal.
IMPORTANT: in humid conditions, such as occur
on most early mornings, do not switch on the blower
prior to servicing the filters. Damp particles drawn
into the filter may solidify and prove difficult to
remove without washing.
The filter element is made of specially treated paper
with a sealing strip bonded to the outer face.
Clean this element by blowing with compressed air
from the clean side through to the dirty side. The
compressed air should not exceed 2 bar (29 psi)
and the air line nozzle should be at least 300 mm
(11.8 in) from the element.
HEATER RADIATOR
The heater radiator (1) is fitted in a housing under
the cab seat to guarantee a uniform distribution of
warm or cold air flow.
IMPORTANT: to ensure a good flow of air through
the heater radiator the filter should be cleaned more
frequently when operating in extremely dusty conditions.
Copyright
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 operators
head (E).
NOTE: the diffusers (B) and (E) are mounted only
when air conditioning (optional) is fitted.
Copyright
8
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;
- 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.
Copyright
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.
Copyright
10
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).
Copyright
11
TROUBLESHOOTING
Items that may cause trouble are listed in the table
below. Anyway, as a general rule, we recommend
carrying out some preliminary checks.
Ensure water flow to the heater radiator is steady
and all air has been removed from the system.
Hoses are unrestricted and not leaking.
Check the electric connections are good and the
blower motor is operational.
The operating cable to the heater valve and valve is
operational.
TROUBLE
Dust enters the cab.
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.
Copyright
12
AIR CONDITIONING
PRINCIPLES OF AIR CONDITIONING
The function of the air conditioning system is to
improve the operators comfort by cooling down the
air temperature inside the cab and reducing the
humidity level.
In order to achieve this heat transfer the following
principals of heat generation and transfer are
applied within the air conditioning system.
When two bodies with a different temperature come
together, heat is transferred from one to the other.
On air conditioning systems, an evaporator is used
to maintain the low temperature of the coolant,
which absorbs the heat from the air within the cab.
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.
Copyright
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.
13
Copyright
14
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
Copyright
LOW PRESSURE SIDE
15
HIGH PRESSURE SIDE
EXPANSION
VALVE
LOW
TEMPERATURE
HIGH PRESSURE
LIQUID FILTERED
AND MOISTURE
REMOVED
LIQUID ATOMIZED
AT A LOWER
TEMPERATURE
RECEIVER DRYER
LOWER
TEMPERATURE
HIGH PRESSURE
LIQUID
EVAPORATOR
CONDENSER
WARM LOW
PRESSURE
VAPOUR
HIGH
TEMPERATURE
HIGH PRESSURE
VAPOUR
COMPRESSOR
HEAT FROM INSIDE
CAB MOVES TO
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.
Copyright
16
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.
Copyright
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.
17
Copyright
18
OPERATION
COOLANT
To achieve the absorption and the release of heat
which is, in essence, the function of an air conditioning system, requires the use of a suitable coolant a liquid that has a relatively low temperature
boiling point, plus certain desirable safety and stability features.
The coolant used in the air conditioning system is
coolant HFC 134a.
NOTE: to help protect the environment legislation
has been introduced in most territories banning the
release into the atmosphere of coolants, including
HFC 134a. All service procedures contained in this
manual can be carried out without the need to
release coolant into the atmosphere.
In order to prevent the incorrect type of coolant
being charged to the system the service valves fitted to the Backhoe Loader and necessary to connect up coolant recovery, evacuation and recycling/
re-charging equipment will be of two different sizes
as recognized and specified by the air conditioning
industry.
WARNING
Coolant HFC 134a is not compatible with coolant
R-12. Do not try to replace coolant HFC 134a with
coolant R-12 or to test the system using instruments or tools previously used with R12, as the
system could get damaged.
HFC 134a coolant is stable at all operating temperatures and able to absorb great quantities of heat.
The boiling point of HFC 134a is -22 C (-7.6 F) at
atmospheric pressure.
If the pressure is increased, HFC 134a will readily vaporize to absorb heat at temperatures
between -11.7 C (10.94 F) at 1.9 bar (28 psi)
and 0 C (32 F) at 2.9 bar (42 psi) in the evaporator.
At higher pressures, HFC 134a will condense and
give off heat at temperatures between 48 C
(118.4 F) at 12.4 bar (180 psi) and 58 C
(136.4 F) at 15.85 bar (230 psi) in the condenser.
WARNING
HFC 134a can be dangerous if improperly handled.
Therefore it is important the following warning and
directions are adhered to.
Never expose any part of the air-conditioner system
to flame or excessive heat because of risk of fire or
explosion, and the production of phosgene gas.
Never disconnect or disassemble any part of the airconditioning system as escaping coolant can cause
frostbite.
WARNING
If coolant should contact the skin use the same
treatment as for frostbite.
Warm the area with your hand or lukewarm water
32 C (89.6 F), cover the area loosely with a bandage to protect affected area against infection and
consult a doctor immediately.
If coolant should contact the eyes wash immediately in cold clean water for at least 5 minutes and
consult a doctor immediately.
Copyright
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.
19
Copyright
20
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.
Copyright
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.
21
Copyright
22
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.
Copyright
The other passage is in the coolant line from the

evaporator to the compressor and contains the
valves 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.
23
Copyright
24
EVAPORATOR
The evaporator is located beneath the cab seat and
consists of a number of turns of continuous coils
mounted in a series of thin cooling fins to provide a
maximum of heat transfer in a minimum amount of
space.
Low temperature coolant in the evaporator absorbs
heat from the hotter air in the operators compartment, thereby cooling the air.
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 operators
feet.
Copyright
25
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.
Copyright
26
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.
Copyright
27
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)
Copyright
28
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.
Copyright
29
PERFORMANCE TEST DIAGNOSIS CHART

TROUBLE
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.
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:
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
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.
Copyright
30

Low pressure - High

High Pressure - Low
TROUBLE
CAUSE
Internal leak in compressor (reed

valves, gasket, worn or scored piston
rings or cylinder).
ACTION
Replace the compressor.
Drain the system.
Charge the system.
Re-test.

Low pressure - Normal

High Pressure - Normal
TROUBLE
CAUSE
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.
Repair leaks.
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.
Copyright
31
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)).
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.
Copyright
32
1. High side low

connector

connector
7. Low side normal
4. Not used
Problem
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.
Drain the system.
Charge the system.
The gauge should read 13.3 14.8 bar ((193 215

psi)).
System coolant is extremely low. A serious leak is

indicated.
Low pressure switch cutting out.
Diagnostic

chart.
Copyright
33
1. High side normal

connector

connector
7. Low side low
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)).

Repair leaks.
Drain the system.
Charge the system.
Diagnostic
Air or moisture in system. System not fully charged.
chart.
Copyright
34
1. High side low

connector

connector
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)).

chart.
Copyright
35
1. High side high

connector

connector
7. Low side high
4. Not used
Problem
Little or no cooling. Engine overheats in some
cases.
Cause
Condenser not functioning properly.
Conditions*
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.
High pressure switch cutting out.
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).
chart.
Copyright
36
1. High side normal

connector

connector
7. Low side normal
4. Not used
Problem
Cause
Large amount of air in system.
Conditions*
1 2 bar (14.5 29 psi).
should read 13.3 14.8 bar (193 215 psi).
Drain the system.
Charge the system.
Diagnostic
Air in the system. Air and humidity contained in it
contaminate the system: therefore, it will operate
incorrectly.
chart.
Copyright
37
1. High side high

connector

connector
7. Low side high
4. Not used
Problem
If the test indicates that the expansion valve is

defective, proceed as follows:
Cause
Improper operation of thermostatic expansion valve

(stuck open).
- replace the expansion valve;
Conditions*
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 and suction hose (to compressor) surfaces show considerable moisture.
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;
Diagnostic
Thermostatic expansion valve is allowing too much
coolant to flow through the evaporator coils. Valve
may be stuck open.
chart.
Copyright
38
1. High side low

connector

connector
7. Low side low
4. Not used
Problem

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;
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)).
Evaporator air cool, but not sufficiently cold.

Evaporator inlet pipe surface shows considerable
moisture or frost.
Low pressure switch cutting out.
Place finger on expansion valve to evaporator tube.
If too cold to touch, proceed as follows:

Diagnostic
Expansion valve is not permitting a sufficient flow of
coolant. May be caused by valve stuck in restricted
or closed position.
chart.
Copyright
39
1. High side low

connector

connector
7. Low side low
4. Not used
Problem
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).

If the test indicates that the expansion valve is
defective, proceed as follows:

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.
Evaporator only slightly cool.

Liquid line and receiver/dryer are cool to touch and
show frost or considerable moisture.
Check for sticking expansion valve as follows:

Diagnostic
Thermostatic expansion valve is allowing too much
coolant to flow through the evaporator coils. Valve
may be stuck open.
chart.
Copyright
40
1. High side normal

connector

connector
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 switchs temperature sensor is

installed in the same position and depth (in evaporator core) as previous.
Diagnostic
Defective thermostatic switch.
chart.
Copyright
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 manufacturers instructions.
Leak detectors use light or sound dependent upon
the type used to alert the operator of a leak. If the
leak detectors sensitivity is adjustable, be sure you
calibrate the detector according to the manufacturers instructions before use.
When using a leak detector, keep in mind that a
very slight amount of leakage in the compressor
pulley area is normal and does not necessarily indicate a repair is required.
When a leak is located, follow these steps.
- 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 manufacturers 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.
41
Copyright
42
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 vehicles air conditioning system for a few
minutes.
Set up the recovery unit following manufacturers
instructions. Ensure that the units red (high side)
hose is connected to the high side (discharge) fit-
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 units power cord.
Operate the recovery system in accordance with
the manufacturers instructions.
The compressor will shut off automatically when the
recovery is complete.
Copyright
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.
43
Copyright
44
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 manufacturers recommendations and directions for using the flushing
equipment and solvent.
Re-assemble and evacuate the system to remove
air and moisture as described in Evacuating the
System.
Copyright
45
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.
Copyright
46
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)
Copyright
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.
47
Copyright
48
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.
Copyright
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.
49
Copyright
50
CONDENSER
Loosen and remove the fixing screws (2).
Remove the front grill (1).

Remove the horn (4).
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).
Copyright
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.
51
Copyright
52
COMPRESSOR
Basic compressor specifications
Displacement ......................................................................................................................... 155 cm3 (9.46 in3)
Weight ............................................................................................................................................ 9.9 kg (22 lb)
Oil type ....................................................................................................................................................... SP20
Rotation .............................................................................................................................. CW (Clockwise only)
Compressor clutch and pulley air gap ............................................................... 0.9 0.8 mm (0.035 0.031 in)
Belt tension
Measure at the widest gap ...... 10 mm (0.40 in) deflection with 1 kg (2.2 lb) force applied midway between the pulleys
Speed rating
Constant............................................................................................................................................... 6000 rpm
Downshift ............................................................................................................................................. 8000 rpm
Tightening torque
M8 armature retaining nut .....................................................................................17.7 2.9 Nm (13 2.1 lbfft)
M6 cylinder head screws.......................................................................................13.7 2.9 Nm (10 2.1 lbfft)
M8 cylinder head screws....................................................................................34.3 4.9 Nm (25.3 3.6 lbfft)
Clutch dust cover screw ...............................................................................................9 2 Nm (6.6 1.5 lbfft)
Oil filler plug .......................................................................................................19.6 4.9 Nm (14.5 3.6 lbfft)
Copyright
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).
53
Copyright
54
Remove the washers (5), the nut (6), the screw (2)
and the block (8).
Remove the screw (1), the washers (3) and the belt
tensioner (4).
Remove the screw (10), the washers (2) and the
compressor (12).
INSTALLATION
To install, follow the removal procedure in reverse
order.
Torque the fastening screws to 40 51 Nm
(29 38 lbfft).
NOTE: it is recommended that a new receiver/drier
assembly is installed after any system component
replacement or any repair that requires entry into
the system.
Drain the oil from the new compressor to be fitted
into a clean container, or if the old compressor is to
be refitted, obtain a new can of coolant oil.
Calculate the amount of oil to be installed and refill
the compressor.
Reconnect the hoses to the compressor and tighten
all screws and hoses.
Copyright
BELT ADJUSTMENT
The compressor drive belt (1) can be tensioned by
rotating the idler arm (2).
Slacken the idler arm screw and adjust the arm to a
belt deflection of 16 mm (0.63 in).
Once adjusted re-torque the tension arm screw to
33.9 Nm (25 lbfft).
OVERHAUL
Before any internal repair is done, drain the oil from
the compressor:
Remove the oil plug and drain as much oil as possible into a suitable container.
Remove the caps (if present) from suction and discharge ports.
Drain oil from the section and discharge ports into
suitable container while turning the shaft clockwise
only with a socket wrench on the armature retaining
nut.
Measure and record the amount of oil discharged.

Inspect the oil for signs of contamination such as
discoloration of foreign material.
55
Copyright
56

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.
Copyright
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.
Copyright
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.
Reposition the plate (4) and the retaining nut (3).

Tighten the nut to the prescribed torque of 18 Nm
(13 lbfft).
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).
Copyright
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).
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.

If the snap ring has a bevelled edge, this should
face outwards.
Install the new ring (2) and push into position.
Copyright
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 lbfft).
When the overhaul is complete add to the compressor a volume of oil equivalent to that drained prior to
disassembly, or as the reclaim measured fill.
Copyright
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

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
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
Copyright
2
ALTERNATOR .............................................................................................................................................. 135

OPERATION ............................................................................................................................................ 136
BATTERY...................................................................................................................................................... 138
OPERATION ............................................................................................................................................ 138
REPLACEMENT ...................................................................................................................................... 139
CHARGE AND ELECTROLYTE LEVEL CHECK .................................................................................... 140
CONNECTING A BOOSTER BATTERY ................................................................................................. 141
BATTERY MASTER SWITCH ................................................................................................................. 141
Copyright
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
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
Copyright
NAME
DESCRIPTION
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

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

(optional)
X44
2-way front right work light connector
Copyright
6
NAME
DESCRIPTION
X45

(optional)
X46
2-way rear left work light connector

(optional)
X47
X50
2-way front left work light connector

(optional)
X51
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
ENGINE LINE DIAGRAM
Copyright
8
SOLENOID VALVE LINE DIAGRAM
Copyright
Copyright
10
LIGHT LINE DIAGRAM
Copyright
REAR LIGHT LINE DIAGRAM
11
Copyright
12
WORK LIGHT LINE DIAGRAM
Copyright
ROTATING BEACON LINE DIAGRAM
13
Copyright
14
BACKHOE ATTACHMENT QUICK COUPLER LINE DIAGRAM
Quick coupler (optional)

See solenoid valve line
Copyright
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
106 C (223 F)
(Red/green line)
93 97 Ohm
Ascending
11 V
Red/green left line
10.7 11.3 V
Descending
15.9 V
Red/green right line
15.0 15.6 V
Ascending
Copyright
PIN
NAME
17
FUNCTION
Ignition
10 V 16 V INPUT
Low oil pressure
Low side switch input
Air filter restriction
Parking brake
Alternator/battery
Alternator D+ input
Not used
Not used
Neutral
High side switch input
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
Transmission temperature
23
Not used
24
Driving lights
25
Not used
26
Not used
27
Not used
28
Not used
29
Not used
30
Not used
31
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

plate light
F3C
10 A

F4A
5A
Reverse travel buzzer, gearshift lever,

forward gear, reverse gear
F4B
10 A
button
F4C
10 A
switch
F5A
15 A
F5B
10 A
Low beams
F5C
15 A
Main beams
F6A
7.5 A
Rotating beacon
F6B
7.5 A
F6C
7.5 A
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
Copyright
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

(optional)
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

(optional)
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

connector
X12
9-way general line - upper cab line

connector
X13

panel connector
X14

S205a Clutch disconnect button
ST3
X55
Current intake
Y3
Fuel shut off solenoid valve
Y6
Y7
Y8
4WD solenoid valve (optional)
Y12
Y34
Y35
DESCRIPTION

X17
X19
X21
7-way left light / horn connector
X22
5-way right light connector
Copyright
NAME
DESCRIPTION
X24
X26
X27
X28
X29
X31
X34

connector
X35

connector
X36
X38
X39
4-way rear windshield wiper connector
X40

(optional)
X44
X45

(optional)
X46

(optional)
NAME
21
DESCRIPTION
X69

connector
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

X102
Diode connector
X103
Diode connector
X104
Diode connector
X105

connector
X106
X110
2-way air conditioner connector
X111
X125
X47
X140
Diode connector
X49
6-way front windshield wiper connector
X202
X50

(optional)

X203

valve connector
X204
2-way horn button on pilot control

connector
X205
X206
X207

connector
X208
X209

connector
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

connector
X67
X68
3-way engine water temperature switch

connector
Copyright
22
NAME
DESCRIPTION
X420
X421
X600
X603

connector

XC1
XC2
XC3
XC4
XC5
XC6
X01
XX
Diode connector

connector
Copyright
ENGINE LINE DIAGRAM
23
Copyright
24
Copyright
25
Copyright
26
LIGHT LINE DIAGRAM
Copyright
REAR LIGHT LINE DIAGRAM
27
Copyright
28
Copyright
WINDSHIELD WIPER - WASHER LINE DIAGRAM
29
Copyright
30
CAB LINE DIAGRAM
Copyright
AIR CONDITIONER DIAGRAM
Evaporator box
S45
11-way connector
3rd speed relay
Potentiometer
Fuse 25 A
10
Speed switch
Blower motor
11
Temperature switch
1 and 2 speed resistor
12
12 V light
Electric cock
2-way waterproof connection
X111
9-way connector
X110
2-way power connector
31
Copyright
32
See Solenoid valve line

Copyright
COLD START LINE DIAGRAM
33
Copyright
34
INSTRUMENT
Speedometer
Level fuel
Transmission
temperature
Coolant
temperature
Battery charge
INPUT
READING
TOLERANCE
INPUT
TOLERANCE
CALIBRATION
DIRECTION
0 Hz
0 rpm
3 rpm
N/A
Descending
307 Hz
1000 rpm
N/A
60 rpm
Ascending
736 Hz
2400 rpm
N/A
60 rpm
Ascending
240 Ohm
Empty
+0/-6 Ohm
230-240 Ohm
Descending
102 Ohm
1/2 Tank
3 Ohm
98 108 Ohm
Descending
33 Ohm
Full
+4/-2 Ohm
33 42 Ohm
Ascending
900 Ohm
Point B
+0/-6 C (32/21.2
F)
N/A
Descending
114 Ohm
106 C (223 F)
(Red/green line)
5 C (41 F)
111 117 Ohm
Ascending
700 Ohm
Point A
+0/-5 C (32/23 F)
N/A
Descending
95 Ohm
106 C (223 F)
(Red/green line)
93 97 Ohm
Ascending
11 V
Red/green left line
10.7 11.3 V
Descending
15.9 V
Red/green right line
15.0 15.6 V
Ascending
Copyright
PIN
NAME
35
FUNCTION
Ignition
10 V 16 V INPUT
Low oil pressure
Air filter restriction
Parking brake
Alternator/battery
Alternator D+ input
Not used
Not used
Neutral
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
Transmission temperature
23
Not used
24
Driving lights
25
Not used
26
Not used
27
Not used
28
Not used
29
Not used
30
Not used
31
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

plate light
F3C
10 A

F4A
5A
Forward travel, reverse travel, reverse

travel buzzer, gearshift control
F4B
10 A
button
F4C
10 A
switch
F5A
15 A
F5B
10 A
Low beams
F5C
15 A
Main beams
F6A
7.5 A
Rotating beacon
F6B
7.5 A
F6C
7.5 A
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
Copyright
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

(optional)
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
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

(optional)
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

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

connector
X12

connector
Copyright
NAME
DESCRIPTION
X13

panel connector
X14

NAME
39
DESCRIPTION
X51
X53
X54
X55
X56
X57
X64

connector
X17
X19
X22
5-way right work light connector
X24
X67
X25
Foot accelerator connector
X69
X26

connector
X27
X72
X28
X87

X29
X88
X31

X34

connector
X102
Diode connector
X103
Diode connector
X35

connector
X104
Diode connector
X36
X105

connector
X38
X106
Engine control unit connector
X39
X106
X40

(optional)
X107
Water in fuel connector
X41
2-way blower connector (optional)
X110
X43
X111
X44
X125
X45

(optional)
X140
Diode connector
X200
X46

(optional)
X47
X49
X50

(optional)
X201.s Accelerator knob connector

X201.p Accelerator knob connector
X202

X203

valve connector
X204

connector
Copyright
40
NAME
DESCRIPTION
X205
X206
X207

connector
X208
X209

connector
X210
X220
Air conditioning connector
X401
X406
X411
X412
X420
X421
X603

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

connector
connector
Copyright
ENGINE LINE DIAGRAM
41
Copyright
42
Copyright
43
Copyright
44
LIGHT LINE DIAGRAM
Copyright
REAR WORK LIGHT LINE DIAGRAM
45
Copyright
46
Copyright
WINDSHIELD WIPER AND WASHER LINE DIAGRAM
47
Copyright
48
CAB LINE DIAGRAM
Copyright
AIR CONDITIONING LINE DIAGRAM
Evaporator box
S45
11-way connector
3rd speed relay
Potentiometer
Fuse 25 A
10
Speed switch
Blower motor
11
Temperature switch
12
12 V light
Electric cock
X111
9-way connector
X110
49
Copyright
50

Copyright
51
Copyright
52
INSTRUMENT
Level fuel
Low fuel level (lamp)

Speedometer
Coolant temperature
Battery charge
Transmission
temperature
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
16 V
Edge of upper red band
385 Ohm
3 C ( 37.4 F)
149 Ohm
2 C ( 35.6 F)
112 Ohm
3 C ( 37.4 F)
Copyright
CN1
PIN
FUNCTION
53
CN2
NOTE
Not used
Key on power
Wake up
In gear input
Digital input
Driving lights
Digital input
Front work lights
Digital input
Rear work lights
Digital input
Not used
Not used
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
Keep alive power
Not used
Can Bus line input
Can Bus line input
Not used
Buzzer
Starter motor lock
Not used
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
Transmission
temperature
17
Not used
15
Not used
18
Parking brake
16
Foot accelerator
0.5 4.5 V
19
Not used
17
Accelerator knob
0.5 4.5 V
20
Minimum
confirmation switch
Digital input
18
Foot accelerator
Output monitored
for diagnostics
21
Decelerator button
Digital input
19
Accelerator knob
Output monitored
for diagnostics
22
Not used
20
Foot accelerator
23
Not used
21
Accelerator knob
24
Not used
22
Not used
25
Transmission oil
pressure
23
Not used
26
Not used
24
Alternator excitation
25
Not used
26
Ground
Digital input
Digital input
Need to fuse at 1
ampere without
disconnect
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

backlighting
F3B
3A

plate light
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
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
Copyright
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

(optional)
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

(optional)
S136
Menu scroll switch
Y206
S137
Y207
S138
Y209
S139
S140
Rear travel switch
S141
S144
Rear horn button

S400
Gearshift lever
S604
SB1
ST1
Copyright
57
CONNECTORS
NAME
DESCRIPTION
NAME
DESCRIPTION
X41
X43
X44
X45

(optional)
X10

connector
X46

(optional)
X12

connector
X47
X13

panel connector
X49
X50

(optional)
X51
X53
X54
X55
X56
X57
X64

connector
X67
X69

connector
X72
X87

X1
X2
X4
X7
X14

X17
X21
X22
X23
Front instrument panel line - general line

interface connector
X24
X25
X26
X27
X28
X29
X31
X88
X34

connector

X102
Diode connector
X103
Diode connector
X104
Diode connector
X105

connector
X35

connector
X36
X38
X39
X106
X40

(optional)
X106
X107
Copyright
58
NAME
DESCRIPTION
NAME
DESCRIPTION
X110
X600
X111
X603
X125

connector

X202

X203

valve connector
X204

connector
X205
X206
X207

connector
X208
X209

connector
X210
X220
X226
Connector (optional)
X400
X401
Transmission control unit connector
X402
Transmission line - Carraro transmission

line connector
X403

line connector
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

line connector
X412
X420
X421

X606
Buzzer connector
X608
Manual accelerator connector
XC1
XC2
XC3
XC4
XC5
XC6
XX
Diode connector

connector
connector
Copyright
ENGINE LINE DIAGRAM
59
Copyright
60
TRANSMISSION CONTROL UNIT LINE DIAGRAM
Copyright
61
Copyright
62
Copyright
LIGHT LINE DIAGRAM
63
Copyright
64
Copyright
65
Copyright
66
Copyright
CAB LINE DIAGRAM
67
Copyright
68
AIR CONDITIONING LINE DIAGRAM
Evaporator box
S45
11-way connector
3rd speed relay
Potentiometer
Fuse 25 A
10
Speed switch
Blower motor
11
Temperature switch
12
12 V light
Electric cock
X111
9-way connector
X110
Copyright

69
Copyright
70
Copyright
71
INSTRUMENT
Level fuel

Speedometer
Coolant temperature
Battery charge
Transmission
temperature
INPUT
READING
TOLERANCE
320 Ohm
+0/-2 Ohm
185 Ohm
3 Ohm (Ref)
6.5 Ohm
+4/-0 Ohm
193 Ohm
ON
5 Ohm
185 Ohm
OFF
5 Ohm
Can message
0 - 3000 rpm
50 rpm
Can message
3 C ( 37.4 F)
Can message
2 C ( 35.6 F)
Can message
3 C ( 37.4 F)
11 V
16 V
385 Ohm
3 C ( 37.4 F)
149 Ohm
2 C ( 35.6 F)
112 Ohm
3 C ( 37.4 F)
Copyright
72
CN1
PIN
FUNCTION
CN2
NOTE
Not used
Key on power
Wake up
In gear input
Digital input
Driving lights
Digital input
Front work lights
Digital input
Rear work lights
Digital input
Not used
Not used
Not used
10
Air conditioning
pressure
Digital input
11
Digital input
12
Menu confirmation
switch input
Digital input
13
UP switch input
14
PIN
FUNCTION
NOTE
Keep alive power
Not used
Can Bus line input
Can Bus line input
Not used
Buzzer
Starter motor lock
Not used
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
Transmission
temperature
17
Not used
15
Not used
18
Parking brake
16
Foot accelerator
0.5 4.5 V
19
Not used
17
Accelerator knob
0.5 4.5 V
20
Minimum
confirmation switch
Digital input
18
Foot accelerator
Output monitored
for diagnostics
21
Decelerator button
Digital input
19
Accelerator knob
Output monitored
for diagnostics
22
Not used
20
Foot accelerator
23
Not used
21
Accelerator knob
24
Not used
22
Not used
25
Transmission oil
pressure
23
Not used
26
Not used
24
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
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

backlighting
F3B
3A

plate light
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
switch
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

(optional)
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
Transmission temperature sensor
B109
Pressure switch
B112
Speed sensor
B608
Accelerator knob
BS1
Left speaker
BS2
Right speaker
E2
Copyright
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

(optional)
S139
Y206
S140
Rear travel switch
Y207
S141
Y209
S144
Rear horn button

S400
Gearshift lever
S404
Copyright
76
CONNECTORS
NAME
DESCRIPTION
X1
X2
X4
X5
Fuel level indicator connector
X7
X10

connector
X12

connector
X13

panel connector
X14

X17
X21
X22
X23
Front instrument panel line - general line

interface connector
X24
X25
X26
X27
X28
X29
X31
X34

connector
X35

connector
X36
X38
X39
X40

(optional)
NAME
DESCRIPTION
X41
X43
X44
X45

(optional)
X46

(optional)
X47
X49
X50

(optional)
X51
X53
X54
X55
X56
X57
X64

connector
X67
X69

connector
X72
X87

X88

Copyright
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

line connector
X95
Steering control unit connector
X403

line connector
X96
Steering control unit connector
X404
X97
Front axle connector

line 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

connector
X409

line connector
X106
X412
X106
X420
X107
X421
X110
Air conditioner connector
X600
X111
Air conditioner connector
X603

connector
X125
X606
Buzzer connector
X608
Accelerator knob connector
X202

XC1
X203

valve connector
XC2
XC3
XC4
XC5
XC6
XX
Diode connector
X204

connector
X205
X206
X207

connector
X208
X209

connector
X210
X220
X226
Connector (optional)

connector
connector
Copyright
78
ENGINE LINE DIAGRAM
Copyright
TRANSMISSION CONTROL UNIT LINE DIAGRAM
79
Copyright
80
4WS STEERING LINE DIAGRAM
Copyright
81
Copyright
82
Copyright
LIGHT LINE DIAGRAM
83
Copyright
84
Copyright
85
Copyright
86
Copyright
CAB LINE DIAGRAM
87
Copyright
88

Copyright
89
Copyright
90
INSTRUMENT
Level fuel

Speedometer
Coolant temperature
Battery charge
Transmission
temperature
INPUT
READING
TOLERANCE
320 Ohm
+0/-2 Ohm
185 Ohm
3 Ohm (Ref)
6.5 Ohm
+4/-0 Ohm
193 Ohm
ON
5 Ohm
185 Ohm
OFF
5 Ohm
Can message
0 - 3000 rpm
50 rpm
Can message
3 C ( 37.4 F)
Can message
2 C ( 35.6 F)
Can message
3 C ( 37.4 F)
11 V
16 V
385 Ohm
3 C ( 37.4 F)
149 Ohm
2 C ( 35.6 F)
112 Ohm
3 C ( 37.4 F)
Copyright
CN1
PIN
FUNCTION
91
CN2
NOTE
Not used
Key on power
Wake up
In gear input
Digital input
Driving lights
Digital input
Front work lights
Digital input
Rear work lights
Digital input
Not used
Not used
Not used
10
Air conditioning
pressure
Digital input
11
Digital input
12
Menu confirmation
switch input
Digital input
13
UP switch input
14
PIN
FUNCTION
NOTE
Keep alive power
Not used
Can Bus line input
Can Bus line input
Not used
Buzzer
Starter motor lock
Not used
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
Transmission
temperature
17
Not used
15
Not used
18
Parking brake
16
Foot accelerator
0.5 4.5 V
19
Not used
17
Accelerator knob
0.5 4.5 V
20
Minimum
confirmation switch
Digital input
18
Foot accelerator
Output monitored
for diagnostics
21
Decelerator button
Digital input
19
Accelerator knob
Output monitored
for diagnostics
22
Not used
20
Foot accelerator
23
Not used
21
Accelerator knob
24
Not used
22
Not used
25
Transmission oil
pressure
23
Not used
26
Not used
24
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
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)
- 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
6. ROLL-OVER
PROTECTION
SWITCH
(Optional)
roll-over protection device. When the operator
is about to start working with the backhoe
attachment in conditions which could cause the
machine to roll over, he/she must activate the
roll-over protection device by pressing the
switch (ON position and lamp turned on).
In this condition, the audible alarm will sound by
means of the buzzer when the pressure switch,
installed on the backhoe attachment boom cylinder, detects a pressure exceeding the following values:
2WS = 116 bar (17 psi)
4WS = 126.5 bar (18 psi)
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
4WD function.
- 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)
- 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
5. ROTATING BEACON SWITCH
This switch is used to turn the rotating beacon
on or off.
6. ROLL-OVER
PROTECTION
SWITCH
(Optional)
roll-over protection device. When the operator
is about to start working with the backhoe
attachment in conditions which could cause the
machine to roll over, he/she must activate the
roll-over protection device by pressing the
switch (ON position and lamp turned on).
In this condition, the audible alarm will sound by
means of the buzzer when the pressure switch,
installed on the backhoe attachment boom cylinder, detects a pressure exceeding the following values:
2WS = 116 bar (17 psi)
4WS = 126.5 bar (18 psi)
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
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

- The first position is OFF (control lamp off).
3. SIDE WORK LIGHT SWITCH (Optional)

- 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
(first click) the instrument cluster panel is
powered, the side lights and the low beam
indicator lamp are turned on (control lamp
on).
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

(first click), the outer rear work lights are
again (second click), the inner rear work
6. SIDE INSTRUMENT CLUSTER
Copyright
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

8. REAR WINDSHIELD WIPER AND WASHER
SWITCH
- 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)
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

3. SIDE WORK LIGHT SWITCH (Optional)


(first click), the outer front work lights are
- Second position, by pressing the symbol

side, the side work lights turn on at the same
time (control lamp on).

again (second click), the inner front work
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
(first click) the instrument cluster panel is
powered, the side lights and the low beam
indicator lamp are turned on (control lamp
on).
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

(first click), the outer rear work lights are
again (second click), the inner rear work
6. SIDE INSTRUMENT CLUSTER
Copyright
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
- 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)
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

Press
on the 2 switches to lock (extend
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
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.
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
7. CRAB (4WS) STEER INDICATOR LAMP

This lamp turns on when crab steer mode is
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
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.
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.
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
(+15) Key positive
Connected to the + 12 V full ignition supply
(+30) Permanent + 12 V power supply
Connected to the wire from the battery positive
(-31) Negative power supply
Connected to the vehicle negative at two independent

points
5-6
Immobilization relay No. 2
Connected in line with the wire controlling the starter

motor relay/solenoid - Minimum 500 mA maximum 10 A
capacity
7-8-9
Immobilization relay No. 1
Connected in line with the cable controlling the ignition

or the fuel system - minimum capacity 500 mA,
maximum capacity 10 A
Copyright
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).
Copyright
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
Copyright
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
Copyright
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.
Copyright
112
WORK HOURS
In order to allow service or the customer to view
vehicle hours of operation, it will not be necessary
to have the key.
By pressing the menu enter/display scroll switch,
with the key turned to OFF, the instrument cluster
panel will activate and display the service hours for
10 seconds.
The hourmeter increments when the engine is running (rpm> 600). The hours are displayed starting
from 0.0 until 210,554,060.7 using an interval of 6
minutes.
In case of battery disconnection, the cluster can
lose 0.1 hour or 6 minutes max.
- 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.
Copyright
113
OPERATION
Auto wake up at every 600 ms for sensing a
change in ENTER, DISPLAY, UP or DOWN switch
status will be provided. Upon sensing of one of
those inputs transition, the cluster has to wake up.
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
Copyright
114
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.
Copyright
115
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%.
external condition.
Loss of voltmeter sensor will be the loss of the
internal VCM A/D converter.
A/D accuracy is specified as 180 mV during self
test operation.
- 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).
- 2.05 V = 115.5 C (240 F).
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.
A stepper motor will drive the transmission oil temperature gauge. The gauge accuracy should be
less than or equal 2%.
external condition. During cranking, the needle
movement shall be frozen in order to inhibit any
spurious movement of it.
Copyright
116
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.
A stepper motor will drive fuel level gauge.
The gauge accuracy should be less than or equal
2%.
external condition.
Copyright
117
WARNING SYSTEM
The diagnostic has to inform the operator regarding
all the operating conditions of the loader backhoe
which are out of range.
These conditions are different from each other:
- warnings;
- error codes;
ALARM ACTIVATION
Non Critical
A failure is present but the operator can continue
his work: the purpose is to warn the operator as
regards the presence of the fault. A beep will sound
every 30 seconds.
- 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 operators attention to the instrument cluster.
Whenever an audible alarm activation is related to

an icon visualization, this icon should remain displayed at least for 4 seconds in order to give the
possibility to the operator to understand the cause
of the alarm activation.
When many warnings with different priority occur,
the audible alarm is related to the higher priority
warning.
When a warning activates with an audible alarm different from the current one, the corresponding icon
must be displayed simultaneously.
If a warning lamp dedicated to a function is associated to the activation cause of the audible alarm,
the warning lamp will activate together with the
audible alarm.
Copyright
118
MAINTENANCE
Two different kinds of maintenance will be available:
- light maintenance;
- heavy maintenance.
LIGHT MAINTENANCE
From 2 hours before the set value, display on the
display the light maintenance symbol at every key
on for 1 second after cranking; after this, the last
selected icon will be visualized on the display. The
hours shown will be the hours when light maintenance is required, not the standard hours displayed
by the hourmeter.
HEAVY MAINTENANCE
From 10 hours before the set value, display on the
display the heavy maintenance symbol at every
key on and should last for 1 second after cranking.
After cranking after this, the last selected icon will
be visualized on the display. The hours shown will
be the hours when light maintenance is required,
not the standard hours displayed by the hourmeter.
Amber-coloured lighting
The interval can be set between 50 and 500 hours
in steps of 100 (0.0, 500, 600, 700, 800, 900,
1000). The 0.0 setting turns the heavy maintenance
feature off.
Amber-coloured lighting
The interval can be set between 50 and 500 hours
in steps of 50 (0.0, 50, 100, 150, 200, 250, 300,
350, 400, 450, 500). The 0.0 setting turns the light
maintenance feature off.
DISPLAY FUNCTION
When the hourmeter reaches the light service interval
3 seconds
3 seconds
GREEN
AMBER
Audible alarm for 1 second when displaying either service interval for the first time
When the hourmeter reaches the heavy service interval
3 seconds
3 seconds
GREEN
AMBER
Audible alarm for 1 second when displaying either service interval for the first time
Since heavy maintenance contains light maintenance the following will be shown:
500 - Light
1000 - Heavy
1500 - Light
2000 - Heavy
The service indicator message will be cleared with a single key cycle
Copyright
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
Red
Malfunction
Continuous
25 seconds
without
message
1053 ECU
Time-out of
message
Red
Malfunction
Continuous
5 seconds
without
message
Time-out of
1054 VCM message engine 1
temperature
Red
Malfunction
Continuous
5 seconds
without
message
Time-out of
1055 VCM message inlet/
exhaust
Red
Malfunction
Continuous
5 seconds
without
message
Time-out of
1056 VCM message engine 1
fluid
Red
Malfunction
Continuous
5 seconds
without
message
Time-out of
1057 VCM message
electric system
Red
Malfunction
Continuous
5 seconds
without
message
1059 VCM
Time-out of
1
message display
Red
Transmission
oil
temperature
too high
Continuous
Transmission
oil above
Transmission oil
115 C
1009 VCM temperature limit 1
(239 F) for 5
reached
seconds
Red
General
display
message
Continuous
DTCs 3000 3366
Only display
with display
request
Red
Copyright
120
Function
Lamp
Alarm
Lamp
Display
lamp
Condition
One touch idle

active
DTC
N/A
SA
Description
Priority Colour
VCM
Red
This prevents
VCM damaging the
parking brake
Continuous,
if vehicle is in
gear
Switch closed
N/A
to ground
Red
Brake
temperature
too high
Continuous
Sender
temperature
Warns customer
over 152 C 1006 VCM before brake
2
(306 F) for 5
fade
seconds
Red
Engine oil
pressure too
high
Continuous
Pressure
depends on
speed
Red
Battery charge
voltage too
high
Continuous
3051 ECU
Battery voltage
too high
Red
Battery charge
voltage too
high
Continuous
Supply
Supply battery
source above
1014 VCM voltage above
16 V for 5
16 V
seconds
Red
Battery charge
voltage too
low
Continuous
3052 ECU
Battery voltage
too low
Red
Continuous
Supply
Supply battery
source below
1015 VCM voltage below
11 V for 5
11 V
seconds
Red
Alternator
unable to
charge
Continuous
Alternator L+
terminal
Alternator
1050 VCM
2
under 1.5 V
unable to charge
for 5 seconds
Red
Accelerator
pedal signal
out of range
One second
alarm every
30 seconds
IVS not
changing
state in 300
ms
Foot accelerator
1010 VCM sensor - not
2
plausible
Amber
Accelerator
pedal signal
out of range
One second
alarm every
30 seconds
Accelerator
Foot accelerator
above 4.75 V 1011 VCM sensor -signal
2
for 5 seconds
above range
Amber
Accelerator
pedal signal
out of range
One second
alarm every
30 seconds
Accelerator
Foot accelerator
under 0.25 V 1012 VCM sensor -signal
2
for 5 seconds
below range
Amber
Parking brake
engaged
Battery charge
voltage too
low
3032 ECU
Copyright
Function
Lamp
Alarm
Lamp
Display
lamp
Condition
DTC
SA
121
Description
Priority Colour
Accelerator
pedal signal
out of range
One second
alarm every
30 seconds
Foot accelerator
1013 VCM sensor - no
2
signal
Amber
Accelerator
pedal signal
out of range
One second
alarm every
30 seconds
Accelerator
Foot accelerator
above 9 V for 1029 VCM sensor - shorted 2
5 seconds
high to Vbat
Amber
Accelerator
pedal signal
out of range
One second
alarm every
30 seconds
Accelerator
Foot accelerator
under 0.5 V 1030 VCM sensor - shorted 2
for 5 seconds
low to Vbat
Amber
5V
accelerator
pedal power
supply
One second
alarm every
30 seconds
Accelerator
Foot accelerator
above 5.1 V 1023 VCM supply voltage
2
for 5 seconds
too high
Amber
5V
accelerator
pedal power
supply
One second
alarm every
30 seconds
Accelerator
Foot accelerator
under 4.9 V 1024 VCM supply voltage
2
for 5 seconds
too low
Amber
5V
accelerator
pedal power
supply
One second
alarm every
30 seconds
Accelerator
Foot accelerator
above 9 V for 1025 VCM supply shorted 2
5 seconds
high to Vbat
Amber
5V
accelerator
pedal power
supply
One second
alarm every
30 seconds
Foot accelerator
Accelerator
supply voltage
under 0.5 V 1026 VCM
2
shorted low to
for 5 seconds
ground
Amber
Accelerator
knob signal
out of range
One second
alarm every
30 seconds
Accelerator
Accelerator
knob sensor above 4.75 V 1035 VCM
signal above
for 5 seconds
range
Amber
Accelerator
knob signal
out of range
One second
alarm every
30 seconds
Accelerator
Accelerator
knob sensor under 0.25 V 1036 VCM
signal above
for 5 seconds
range
Amber
Accelerator
knob signal
out of range
One second
alarm every
30 seconds
Accelerator
1037 VCM knob sensor - no 2
signal
Amber
Copyright
122
Function
Lamp
Alarm
Lamp
Display
lamp
Condition
DTC
SA
Description
Priority Colour
Accelerator
knob signal
out of range
One second
alarm every
30 seconds
Accelerator
Accelerator
knob sensor above 9 V for 1038 VCM
shorted high to
5 seconds
Vbat
Amber
Accelerator
knob signal
out of range
One second
alarm every
30 seconds
Accelerator
Accelerator
knob sensor under 0.5 V 1039 VCM
shorted low to
for 5 seconds
ground
Amber
5V
accelerator
knob power
supply
One second
alarm every
30 seconds
Accelerator
Accelerator
above 5.1 V 1031 VCM knob supply
2
for 5 seconds
voltage too high
Amber
5V
accelerator
knob power
supply
One second
alarm every
30 seconds
Accelerator
Accelerator
under 4.9 V 1032 VCM knob supply
for 5 seconds
voltage too low
Amber
5V
accelerator
knob power
supply
One second
alarm every
30 seconds
Accelerator
Accelerator
knob supply
above 9 V for 1033 VCM
voltage shorted
5 seconds
high
Amber
5V
accelerator
knob power
supply
One second
alarm every
30 seconds
Accelerator
Accelerator
knob supply
under 0.5 V 1034 VCM
voltage shorted
for 5 seconds
low
Amber
Continuous
Switch closed
to ground
with vehicle in N/A
gear and no
parking brake
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
One second
alarm every
30 seconds
Engine
coolant
temperature
too high
One second
alarm every
30 seconds
Coolant
Engine over
above 106 C
operating
1019 VCM
(223 F) for 5
coolant
seconds
temperature
Engine
coolant
temperature
too high
One second
alarm every
30 seconds
Coolant
3007 ECU temperature
signal high
88 C
(1276 F) for
5 seconds
Engine over
1018 VCM operating boost
air temperature
Amber
Amber
Amber
Copyright
Function
Lamp
Alarm
Transmission
oil
temperature
above 105 C
One second
alarm every
30 seconds
Fuel
temperature
too high
One second
alarm every
30 seconds
Fuel
temperature
too high
Lamp
Display
lamp
Condition
DTC
SA
123
Description
Coolant above
Transmission
105 C
1020 VCM over operating
(221 F) for 5
temperature
seconds
Priority Colour
Amber
Fuel over
1021 VCM operating
temperature
Amber
One second
alarm every
30 seconds
Fuel
temperature
3015 ECU
signal source
high
Amber
Fuel
temperature
too high
One second
alarm every
30 seconds
Fuel
3016 ECU temperature
signal no signal
Amber
Clogged air
filter
One second
alarm every
30 seconds
Switch closed
Air filter
threshold
5 seconds
Red
Air
conditioning
not functional
One second
alarm every
30 seconds
Switch closed
Air conditioning
to Vbat for 5 1003 VCM
4
system pressure
seconds
Amber
Hydraulic oil
filter restriction
One second
alarm every
30 seconds
Switch closed
Hydraulic filter
threshold
5 seconds
Red
Fuel
contaminated
with water
One second
alarm every
30 seconds
Display
message
1022 VCM
Amber
Fuel level
sensor
One second
alarm every
30 seconds
Fuel sender
Fuel sender
shorted high above 9 V for 1043 VCM
instrument in
5 seconds
stand-by
Amber
Fuel level
sensor
One second
alarm every
30 seconds
Fuel sender
Fuel sender
shorted low below 0.5 V 1044 VCM
instrument in
for 5 seconds
stand-by
Amber
Fuel level
sensor
One second
alarm every
30 seconds
Input is
switched
battery for 5
seconds
Amber
Fuel over
82 C
(1189 F) for
5 seconds
Fuel sender
open circuit 1045 VCM
instrument in
stand-by
Copyright
124
Function
Lamp
Alarm
Lamp
Display
lamp
Condition
DTC
SA
Description
Priority Colour
Transmission
temperature
sensor
One second
alarm every
30 seconds
Transmission
Transmission
temperature
temperature
sender above 1046 VCM
sender shorted
9 V for 5
high
seconds
Amber
Transmission
temperature
sensor
One second
alarm every
30 seconds
Transmission
Transmission
temperature
temperature
sender below 1047 VCM
sender shorted
0.5 V for 5
low
seconds
Amber
Transmission
temperature
sensor
One second
alarm every
30 seconds
Input is
switched
battery for 5
seconds
Transmission
1048 VCM temperature
open circuit
Amber
Brake
temperature
sensor
One second
alarm every
30 seconds
Brake
Sender over
temperature
1000 Ohm for 1049 VCM
sender out of
5 seconds
range
Amber
General
display
message
One-second
alarm
DTCs 3000 3366
Only display
VCM with display
request
Amber
Low fuel
warning
One-second
alarm
Low fuel - must

stay on for
VCM
remaining key
cycle
Amber
Copyright
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 solenoids 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 manufacturers instructions.

If a testing device of the type indicated is not available, use a standard 0 - 20 V voltmeter and a 0 - 500 A
ammeter to check the operation of the starter motor
on the vehicle.
Before testing:
- 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.
Copyright
126
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
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
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

the body of the starter motor (2).
the motor block (3).
check and retighten the cable connections, check
the ground connections between the starter motor
clamp and the undercarriage.
Ground cable of the battery

the motor block (2).
the negative terminal of the battery (3).
check and retighten the ground cable connections.
Check the voltage again. If it is still excessive,
replace the ground cable.
127
Copyright
128
STARTER MOTOR
Manufacturer .............................................................................................................................................Denso
Voltage .........................................................................................................................................................12 V
Rated power............................................................................................................................................. 2.7 kW
Starting system .......................................................................................................................................Positive
Operating time.............................................................................................................................................. 30 s
Direction of rotation .................................................................................... Clockwise seen from the pinion side
Weight ......................................................................................................................................... 8.4 kg (18.5 lb)
Maximum consumption without load at 11 V and 3000 rpm minimum ...................................... 200 A maximum
Maximum consumption with a torque of 19.6 Nm (14.5 lbfft) at 8 V and 1130 rpm minimum .........600 A maximum
Maximum consumption when shimming at 3 V with a torque of 39.2 Nm (568 lbfft) minimum ......1400 A maximum
MAIN COMPONENTS
1. Motor
2. Induction coils
3. Armature
4. Commutator
5. Brush assembly
6. Pinion gear
7. Intermediate pinion
8. Solenoid
9. Clutch
10. Drive pinion
Copyright
129
Copyright
130
1. Shim
2. Bearing
3. Armature
4. Bearing
5. Coils housing
6. Protection
7. Brush spring
8. Brush assembly
9. Disc
10. Cover
11. Screw
12. Screw
13. Drain
14. Screw
15. Protection
16. Gasket
17. Washer
18. Nut
19. Rod
20. Connection assembly
21. Screw
22. Connection assembly
23. Nut
24. Ring
25. Roller
26. Cage
27. Pinion
28. Ball
29. Spring
30. Drain
31. Screw
32. Washer
33. O-ring
34. Flange
35. Pinion, rings and spring assembly
36. O-ring
37. Bearing
38. Bearing
39. Spring
40. Shaft
41. Body
42. Clutch assembly
Copyright
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.
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.
131
Copyright
132
Armature
The surface of the commutator must be clean and
without traces of burns. If necessary, remove traces
of burns using fine sandpaper. Do not use emery
cloth. Then, clean the commutator with a cloth
soaked in gasoline.
After rectifying the commutator, polish it with fine
sandpaper, then wipe it with a cloth soaked in gasoline.
NOTE: make sure not to graze the metal of the commutator during rectification of insulating notches.
The resistance of the armature insulation may be
checked by connecting an ohmmeter (1) between
the blades of the commutator (2) and the armature
shaft (3). The resistance must be infinite (no continuity).
To check that the armature is not short-circuited, a
special device for armatures must be used. The
other solution is to replace the armature.
If the circumference of the armature has come into
contact with the starter pole shoes, the bearings of
the armature are probably excessively worn out.
First check that the starter pole shoes have been
tightened and that the armature rotates without any
concentric defect. If necessary, replace the armature bearings.
Field coils
To check the resistance of the field coil insulation,
connect an ohmmeter (1) between the brushes of
each induction coil (2) and a clean unpainted area
of the body (3). The resistance must be infinite (no
continuity).
To check the continuity of the field coils, connect an
ohmmeter between the brushes of each induction
coil and the main supply terminal (the thickest
braided wire). The resistance must be equal to 1
MW.
If the field coils are defective, the entire assembly
consisting of the body and the field coils must be
replaced.
Drive pinion
The drive pinion must only rotate clockwise. If the
pinion is seized or turns in both directions or if its
teeth are damaged, change the complete drive
assembly.
NOTE: if the teeth of the drive pinion are damaged,
also check the teeth of the engine flywheel ring
gear.
Copyright
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.
Copyright
134
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.
Copyright
135
ALTERNATOR
Rated voltage ............................................................................................................................................ 14.5 V
Current ...................................................................................................................................................... 120 A
Swing speed ........................................................................................................................ 12000 13500 rpm
Operating temperature ...................................................................................... -30 C 90 C (-435 1305 F)
Direction of rotation .................................................................................... Clockwise seen from the pulley side
Regulated voltage at 5000 rpm with 10 A at 25 C (362 F) .......................................................... 14.2 14.8 V
Maximum load that can be applied at terminal L ........................................................................ 12 V, 3.4 W x 6
Copyright
136
OPERATION
The alternator, installed on the motor, on the front
RH side of the vehicle, is driven by the crankshaft
pulley with the help of a belt.
The alternator contains built-in regulators.
Current draw on the starter motor system:
When the ignition key is turned, a current of low
intensity is sent by the battery to the field winding of
the rotor (terminal IG).
At this stage, the indicator lamp (terminal L) turns
on and the rotor is partially magnetized.
When the motor starts and the partially magnetized
rotor rotates inside the stator, a three-phase alternating current is generated (terminal B+).
A constant portion of this current is transformed into
a direct current by three excitation diodes installed
in the rectifier.
The direct current is sent as reinforcement through
the field winding of the rotor.
Using this method an increase in the magnetic field
of the rotor is obtained, as well as a rapid rise in the
voltage and current generated at the output.
The luminosity of the indicator lamp decreases
when the voltage generated at the output is increasing (terminal L).
The indicator lamp goes out when the voltage at terminal L is equal to that of the battery.
The voltage continues to increase up to the value
predefined by the regulator.
In case the alternator belt is broken, the voltage
does not accumulate in the alternator and the load
indicator lamp remains lighted to indicate the problem.
1. Terminal W
2. Terminal IG
3. Terminal L
4. Terminal B
Copyright
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.
Copyright
138
BATTERY
For the loader backhoe models two different kinds of installation are provided:
- with one battery;
- with two batteries (for cold climates).
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
REPLACEMENT
position.
brake.
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.
This could generate an electrolysis inside the
human body and damage the bodys vital organs.
Place the battery switch in the OFF position.
Remove the battery master switch support (6) without disconnect the battery cables.
Remove the terminal covers and disconnect the
cables, first from the negative terminal (1) then the
positive terminal (2).
Remove the nuts and washers (3), the clamping bar
(4) and the brackets (5) and remove the old battery.
Install the new battery.
Install the brackets (5), the clamping bar (4) and the
washers and nuts (3).
Clean the cables and the connecting terminals and
coat them with grease.
Connect the cables, first to the positive terminal (2),
then the negative terminal (1) and install the terminal covers.
Reassemble the battery master switch support (6).
139
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

This could generate an electrolysis inside the
human body and damage the bodys 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.
Copyright
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 machines battery.
Connect the negative (-) jumper cable to one of the
fastening screws (1) of tank.
Start the engine
First disconnect the negative (-) jumper cable, then
disconnect the positive (+) jumper cable from the
booster battery.
Install the terminal covers.
Install the tool box and close the battery box.
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.
Copyright
142
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.

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.

density.
Malfunctioning alternator.
Check the alternator and repair, if

necessary.
Copyright
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.

density.
Loose or worn belt.
Check the automatic belt tensioner.

If necessary, replace the belt.
Malfunctioning alternator.
Check the alternator and repair, if

necessary.
Copyright
144
NOTES:
Copyright
580T
580ST
590ST
695ST

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
Copyright
2
Copyright
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 operators seat is correctly adjusted in the loader attachment position.
WITH STANDARD LOADER BUCKET
Located on the right of the steering wheel, this nine
position lever operates all the loader attachment
controls.
The speed of movement of each control depends on
the angle to which the lever is tilted. In the intermediate position, two movements can be obtained
simultaneously.
WITH 4x1 LOADER BUCKET
The function of the lever is identical to that of the
machine fitted with the standard loader bucket, with
the addition of the clam control.
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.
Copyright
4
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
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.
Copyright
6
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
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 operators compartment, undertaking any road travel or working with the backhoe
attachment, place the pin in locking position.
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.
Copyright
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).
Copyright
10
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.
Copyright
11
REMOVAL AND INSTALLATION OF LOADER BUCKET

STANDARD LOADER BUCKET
REMOVAL
Lower the bucket to the ground in dump position
(tilted completely forward).
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.
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.
(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.
Copyright
12
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.
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
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

Position the loader bucket so that the bucket teeth
can be replaced.
brake.
Loosen and remove the screws (2) with the nuts (3).
Extract the tooth (1).
Clean the area around the tooth.
Assemble the new tooth (1).
Screw in and tighten the screws (2) with the nuts (3).
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
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
reverse order.
15
Copyright
16
NOTES:
Copyright
580T
580ST
590ST
695ST

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
Copyright
2
Copyright
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;
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
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.
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 operators
seat to the backhoe attachment working position, it
is essential to place the direction-of-travel control
lever and the powershuttle gearshift lever in the
neutral position and immobilize the machine by
means of the parking brake lever.
WARNING
Before using the backhoe controls, make sure that
the operators seat is correctly adjusted in the backhoe attachment position.
Copyright
BACKHOE ATTACHMENT MECHANICAL
CONTROLS
STABILIZER MECHANICAL CONTROLS
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
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.
lever support.
WARNING
Copyright
8
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
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
Copyright
10
ISO configuration
Backhoe dipper and backhoe attachment swing lefthand control lever
Position (A): the backhoe dipper extends.
Position (B): the backhoe dipper retracts.
left.
right.
Backhoe boom and backhoe bucket right-hand control lever
Position (E): the boom lowers.
Position (F): the boom rises.
Copyright
11
Copyright
12
Four-lever pattern configuration

Lever (1) for dipper
Position (A): the backhoe dipper extends.
Position (B): the backhoe dipper retracts.
Lever (2) for boom
Position (C): the boom rises.
Position (D): the boom lowers.
Lever (3) for backhoe bucket
Position (E): the backhoe bucket closes.
Position (F): the backhoe bucket opens.
Lever (4) for backhoe attachment swing
Position (G): the backhoe attachment swings to the
right.
Position (H): the backhoe attachment swings to the
left.
Copyright
13
Copyright
14
Cross-pattern configuration
Backhoe boom and backhoe attachment swing lefthand control lever
left.
right.
control lever
Copyright
15
Copyright
16
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
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.

lever support.
WARNING
17
Copyright
18
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
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
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
CONTROL ENABLE SWITCH
This control is located on the right-hand control
lever.
- 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.
19
Copyright
20
BACKHOE ATTACHMENT HYDRAULIC

CONTROLS
Standard configuration
Backhoe boom and backhoe attachment swing lefthand hydraulic control lever
This hydraulic control lever has five positions:
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.
left.
right.

control lever
This hydraulic control lever has five positions:
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.
Copyright
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.
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.
21
Copyright
22
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
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).
23
Copyright
24
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
HYDRAULIC HANDLING
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.
25
Copyright
26
BACKHOE ATTACHMENT DISASSEMBLY

Park the machine on a flat surface and position the
backhoe on the ground.
WARNING
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
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).
Now it is possible to remove the backhoe attachment from the machine.
27
Copyright
28
BACKHOE BUCKET REPLACEMENT

REMOVAL
Lower the stabilizers until they are resting on the
ground.
Place the bucket on the ground.
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).
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.
Insert pin (3) and install the stop ring (1) and the ring
(2).
Copyright
BACKHOE BUCKET
Position the backhoe bucket so that the bucket teeth
can be replaced.
brake.
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).
29
Copyright
30
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
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.
Copyright
HYDRAULIC DIAGRAM
A. Backhoe attachment control valve

B. Union tee of main load-sensing line from backhoe attachment control valve
31
Copyright
32

[Tightening torque = 85 115 Nm
(62.69 84.82 lbfft)]
2. Washer
3. Plate
4. Pin
5. Snap ring
6. Nut M14
7. Support
8. Shoe
9. Shim
10. Handling cylinder assy
[Tightening torque = 135 183 Nm
(99.57 134.97 lbfft)]
12. Washer
13. Spacer
14. Spacer
15. Snap ring
16. Pin
17. Cylinder support
18. Handling cylinder
20. Shim
21. Washer
22. Shoe
23. Shim
24. Fitting
25. M12 x 20 socket head screw
26. Shoe
Copyright
HANDLING CYLINDER
1. Stroke
33
Copyright
34
NOTES:

Case T-Series TLB en

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Case T-Series TLB en

Uploaded by

Copyright:

Available Formats

Copyright

Print No. 84428671A

CNH ITALIA S.p.A.

For any question or remark, or in case of any

The Service Manuals for Backhoe loader and

Service Manual - Backhoe loader

580T - 580ST - 590ST - 695ST

Service Manual - Engine

580T - 580ST - 590ST - 695ST

A careful operator and / or technician is the best insurance against accidents.

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

CNH ITALIA S.p.A.

BACKHOE LOADER MODELS

Engine Iveco 82 kW - 110 HP model

Engine Iveco 82 kW - 110 HP (4WS) model

Short backhoe dipper

Long backhoe dipper

SECTION 02 - TECHNICAL SPECIFICATIONS

SECTION 25 - FRONT AXLE

SECTION 33 - BRAKE SYSTEM

SECTION 41 - STEERING SYSTEM

SECTION 50 - CAB HEATING AND AIR CONDITIONING

SECTION 84 - BACKHOE ATTACHMENT

SECTION 00 - SAFETY RULES

SECTION 00 - SAFETY RULES

SECTION 00 - SAFETY RULES

SECTION 00 - SAFETY RULES

SECTION 00 - SAFETY RULES

PREVENTION OF FIRE OR EXPLOSIONS

A spark or a flame can cause the electrolyte of the

Hot coolant could spray out if the radiator cap is

SECTION 00 - SAFETY RULES

PRECAUTIONS FOR WASTE DISPOSAL

Move the machine to a level and firm ground, away

SECTION 02 - TECHNICAL SPECIFICATIONS

Engine Iveco 82 kW - 110 HP model

Engine Iveco 82 kW - 110 HP (4WS) model

Short backhoe dipper

Long backhoe dipper

SECTION 02 - TECHNICAL SPECIFICATIONS

IDENTIFICATION OF MAIN COMPONENTS

9. Dipper / telescopic dipper of backhoe

10. Backhoe bucket

11. Backhoe attachment sideshift carriage

13. Battery box

14. Hydraulic oil tank

8. Backhoe attachment boom

9. Dipper / telescopic dipper of backhoe

10. Backhoe bucket

11. Backhoe attachment sideshift carriage

13. Battery box

14. Hydraulic oil tank

8. Backhoe attachment boom

SECTION 02 - TECHNICAL SPECIFICATIONS

SECTION 02 - TECHNICAL SPECIFICATIONS

82 kW - 110 HP ENGINE (590ST / 695ST)

reverse travel 4.643:1

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

reverse travel 2.884:1

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

reverse travel 1.313:1

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

reverse travel 0.657:1