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Case 580SR, Service Manual

The Case 580SR is a versatile and reliable construction equipment. For detailed instructions on maintenance and repair, download the free Service Manual from manualshive.com. This manual will provide you with all the information you need to keep your Case 580SR running smoothly for years to come.

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3.8 COMPONENTS OVERHAUL .............................................................................................................. 48
3.9 COMPRESSOR ................................................................................................................................... 53
3.10 SPECIAL TOOLS............................................................................................................................... 67

SECTION 55 - ELECTRICAL SYSTEM

1. GENERALITIES............................................................................................................................................ 3

1.1 TEMPORARY WIRING HARNESS REPAIR ......................................................................................... 3
1.2 FAULT FINDING.................................................................................................................................... 4

2. ELECTRICAL DIAGRAMS............................................................................................................................ 5

2.1 ELECTRICAL DIAGRAMS - POWERSHUTTLE ROPS (580SR).......................................................... 5
2.2 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR)........................................................... 20
2.3 ELECTRICAL DIAGRAMS - POWERSHIFT CAB (580SR)................................................................. 36
2.4 ELECTRICAL DIAGRAMS - POWERSHUTTLE CAB (580SR+/590SR) ............................................ 54
2.5 ELECTRICAL DIAGRAMS - POWERSHIFT CAB (590SR)................................................................. 69
2.6 ELECTRICAL DIAGRAMS - 4WS POWERSHIFT CAB (695SR)........................................................ 84

3. CONTROLS AND INSTRUMENTS .......................................................................................................... 100

3.1 FRONT CONTROL PANELS (580SR / 590SR) ................................................................................ 100
3.2 FRONT CONTROL PANELS (695SR) .............................................................................................. 102
3.3 SIDE INSTRUMENT CLUSTER PANEL (580SR) ............................................................................. 104
3.4 SIDE INSTRUMENT CLUSTER PANEL (580SR+ / 590SR / 695SR)............................................... 106
3.5 SIDE INSTRUMENT CLUSTER (580SR).......................................................................................... 108
3.6 SIDE INSTRUMENT CLUSTER (580SR+ / 590SR / 695SR)............................................................ 110
3.7 IMMOBILISER CIRCUIT.................................................................................................................... 112

4. DIAGNOSTIC DISPLAY (580SR+ / 590SR / 695SR) ............................................................................... 113

4.1 SYMBOLS.......................................................................................................................................... 114
4.2 SETUP MENU ................................................................................................................................... 115
4.3 PROCEDURE ABOUT SELF TEST .................................................................................................. 116
4.4 ON BOARD ERROR CODE RETRIEVAL ......................................................................................... 117
4.5 BACKLIGHTING AND DIMMING....................................................................................................... 118
4.6 WORK HOURS.................................................................................................................................. 119
4.7 FUNCTIONAL DESCRIPTION .......................................................................................................... 120
4.8 WARNING SYSTEM.......................................................................................................................... 124
4.9 MAINTENANCE................................................................................................................................. 126
4.10 WARNING MESSAGES .................................................................................................................. 127

5. STARTING SYSTEM ................................................................................................................................ 134

5.1 DESCRIPTION AND OPERATION.................................................................................................... 134
5.2 FAULT FINDING................................................................................................................................ 135
5.3 STARTER MOTOR............................................................................................................................ 138

6. ALTERNATOR.......................................................................................................................................... 144

6.1 SPECIFICATIONS ............................................................................................................................. 144
6.2 DESCRIPTION AND OPERATION.................................................................................................... 144
6.3 COMPONENTS ................................................................................................................................. 146
6.4 REMOVAL ......................................................................................................................................... 147
6.5 PRELIMINARY CHECK AND TESTS................................................................................................ 148
6.6 FAULT FINDING................................................................................................................................ 157

7. BATTERY ................................................................................................................................................. 158

7.1 SPECIFICATIONS ............................................................................................................................. 158
7.2 DESCRIPTION AND OPERATION.................................................................................................... 158
7.3 BATTERY REPLACEMENT .............................................................................................................. 159
7.4 MAINTENANCE................................................................................................................................. 161
7.5 TESTS ............................................................................................................................................... 163

Copyright ©

Summary of Contents for 580SR

Page 1: ...580SR 580SR 590SR 695SR SERIES 3 580SR 580SR 590SR 695SR SERIES 3 Service manual Service manual Print No 87643852B Print No 87643852B www maskinisten net Copyright...

Page 2: ...7 SPICER OFF HIGHWAY AXLE DIVISION 21199 www maskinisten net Copyright...

Page 3: ...nsists of two vol umes Z 580SR 580SR 590SR 695SR Service Manual for Loader backhoe Z 580SR 580SR 590SR 695SR Service Manual Engine The Service Manuals for Loader backhoe and En gine contain the necess...

Page 4: ...ob servance of one simple rule would prevent many thousands of serious injuries each year This rule is never attempt to clean lubricate or adjust a machine while it is in motion S WARNING Before carry...

Page 5: ...O Stabilizer center pivot O Cab O O O O Rops O 2WD O 4WD O O O O 4WS O Pilot control O O O O Mechanical control O O O O Engine 72 kW 97 HP model F4GE948C 601 mechanical O Engine 72 kW 97 HP model F4HE...

Page 6: ...www maskinisten net Copyright...

Page 7: ...T WITH FORKS 19 4 3 BACKHOE ATTACHMENT DIMENSIONS AND PERFORMANCE 20 5 BACKHOE ATTACHMENT LIFTING CAPACITY 26 6 MAXIMUM LIFTING LOADS 29 6 1 LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE 29 6 2 BACKHOE...

Page 8: ...95 2 3 LUBRICATION 105 2 4 PRESSURE SPECIFICATIONS AND CHECK POINTS 106 2 5 TRANSMISSION COOLER 108 2 6 HYDRAULIC DIAGRAM 109 2 7 OPERATION 110 2 8 POWER FLOWS 117 2 9 GEAR AND CLUTCH LAY OUT 132 2 1...

Page 9: ...WS SIDESHIFT MECHANICAL MODELS 7 1 4 HYDRAULIC DIAGRAM 4WS SIDESHIFT PILOT MODELS 9 1 5 HYDRAULIC DIAGRAM 4WS CENTER PIVOT PILOT MODELS 11 2 HYDRAULIC PUMP 13 2 1 DESCRIPTION AND OPERATION 13 2 2 SPEC...

Page 10: ...INSTALLATION COMPONENTS 5 2 1 COMPONENTS WITHIN THE CHASSIS 5 2 2 COMPONENTS BELOW THE CHASSIS 6 2 3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS 8 2 4 COMPONENTS ATTACHED ON THE CHASSIS 9 2 5 MOUNTING SCR...

Page 11: ...PANEL 580SR 590SR 695SR 106 3 5 SIDE INSTRUMENT CLUSTER 580SR 108 3 6 SIDE INSTRUMENT CLUSTER 580SR 590SR 695SR 110 3 7 IMMOBILISER CIRCUIT 112 4 DIAGNOSTIC DISPLAY 580SR 590SR 695SR 113 4 1 SYMBOLS...

Page 12: ...R AXLE STEERING SENSOR 187 8 19 4WS FRONT AXLE STEERING SENSOR 187 8 20 STEERING SOLENOID VALVE 188 8 21 DIFFERENTIAL LOCK SWITCH 1 189 8 22 LOADER 190 8 23 BACKHOE 193 SECTION 82 LOADER 1 LOADER ATTA...

Page 13: ...580SR 580SR 590SR 695SR SECTION 00 SAFETY PRECAUTIONS www maskinisten net Copyright...

Page 14: ...2 SECTION 00 SAFETY PRECAUTIONS www maskinisten net Copyright...

Page 15: ...S Most accidents and personal injuries that occur in the work site or on the road are caused by the failure of some individual to follow simple and fundamental safety rules or precautions For this rea...

Page 16: ...ck wheels Firmly tie the machine to the truck or trailer platform and block wheels as required by the forwarder Z For electrical heaters battery chargers and similar equipment use exclusive auxiliary...

Page 17: ...zards Z Prior to any service check for fuel or coolant leaks Remove these leaks before going on with the work Do not charge batteries in confined spaces En sure that ventilation is appropriate to prev...

Page 18: ...age when draining off used engine cool ant mixtures engine transmission and hydraulic oils brake fluids etc Do not mix drained brake fluids or fuels with lubri cants Store them safely until they can b...

Page 19: ...580SR 580SR 590SR 695SR SECTION 01 MAINTENANCE www maskinisten net Copyright...

Page 20: ...2 SECTION 01 MAINTENANCE www maskinisten net Copyright...

Page 21: ...from the original swagged position have failed and will ultimately sep arate completely A hose with a chafed outer cover will allow water en try Concealed corrosion of the wire reinforcement will subs...

Page 22: ...NOTE a torque wrench is necessary to properly torque hardware NOTES FOR SPARE PARTS Only genuine parts guarantee same quality life safety as original components as they are the same as mounted in prod...

Page 23: ...11 3 10 TYRES 12 4 DIMENSIONS AND PERFORMANCE 13 4 1 LOADER ATTACHMENT DIMENSIONS AND PERFORMANCE 13 4 2 DIMENSIONS AND PERFORMANCE OF LOADER ATTACHMENT WITH FORKS 19 4 3 BACKHOE ATTACHMENT DIMENSIONS...

Page 24: ...2 SECTION 02 TECHNICAL SPECIFICATIONS 1 www maskinisten net Copyright...

Page 25: ...O Cab O O O O Rops O 2WD O 4WD O O O O 4WS O Pilot control O O O O Mechanical control O O O O Engine 72 kW 97 HP model F4GE948C 601 mechanical O Engine 72 kW 97 HP model F4HE0484C J102 electronic O E...

Page 26: ...er bucket 2 Loader arm 3 Front axle 4 Fuel tank 5 Rear axle 6 Operator s compartment 7 Engine guard 8 Backhoe attachment boom 9 Dipper or telescopic dipper 10 Backhoe bucket 11 Backhoe attachment side...

Page 27: ...Loader bucket 2 Loader arm 3 Front axle 4 Fuel tank 5 Rear axle 6 Operator s compartment 7 Engine guard 8 Backhoe attachment boom 9 Dipper or telescopic dipper 10 Backhoe bucket 11 Stabilizers 12 Batt...

Page 28: ...rcooler 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 Tempe...

Page 29: ...Valves per cylinder 4 Bore 104 mm Stroke 132 mm Displacement 4485 cm3 Compression ratio 17 5 1 Maximum torque EC 516 Nm 1400 rpm Low idle speed at no load 950 50 rpm High idle speed at no load engine...

Page 30: ...80SR 590SR Model Dana T16000 Type 4x4 4 forward and 2 reverse travel gears Torque converter ratio 2 261 Transmission ratios upper output 1st forward travel gear 4 863 1 reverse travel gear 4 085 1 2nd...

Page 31: ...id Differential lock powershuttle axle mechanical Differential lock powershift axle electrical Rear 4WS axle 695SR Model CARRARO 26 32M Type steering Differential lock electrical 3 4 BRAKES BRAKES 2WS...

Page 32: ...rev Shock valve adjustment 225 bar Pressure relief valve adjustment 170 bar 3 6 HYDRAULIC SYSTEM HYDRAULIC PUMP Pump 72 kW 97 HP 580SR Model CASAPPA KP 30 34 05 S6 LMF Type double gear pump hydraulic...

Page 33: ...n 2 5 m s2 Abdomen level lower than 0 5 m s2 3 9 BUCKETS LOADER BUCKETS BACKHOE BUCKETS 2WS Type 0 88 m3 standard 1 m3 standard 4x1 6x1 with forks Heaped capacity 0 88 m3 1 0 m3 1 0 m3 1 0 m3 Width 2...

Page 34: ...and rear nuts 4WS 700 Nm Front tyres Rear tyres 2WD 11L 16 F3 12PR 18 4 26 R4 12PR 11L 16 F3 12PR 16 9 28 R4 12PR 4WD 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...

Page 35: ...ing height D Angle of lowered closed bucket E Angle of closed bucket at maximum height F Loader attachment reach when raised in dump ing position G Cab height H Digging depth I Loader bucket reach J W...

Page 36: ...2950 mm H 240 mm 120 mm I 2060 mm 1973 mm J 2175 mm 2175 mm K 1325 mm 1325 mm L 1630 mm 1630 mm M 5865 mm 5778 mm N 4000 mm 4000 mm P 2430 mm 2430 mm Q 2250 mm 2250 mm Performance 2WD 4WD Lifting capa...

Page 37: ...ket E Angle of closed bucket at maximum height F Loader attachment reach when raised in dump ing position G Cab height H Digging depth I Loader bucket reach J Wheel base K Rear wheel base backhoe atta...

Page 38: ...J 2200 mm 2200 mm 2200 mm K 1324 mm 1324 mm 1324 mm L 1630 mm 1630 mm 1630 mm M 5783 mm 5788 mm 5788 mm N 3935 mm 3935 mm 3935 mm P 2480 mm 2480 mm 2480 mm Q 2400 mm 2400 mm 2400 mm Performance Stand...

Page 39: ...ucket E Angle of closed bucket at maximum height F Loader attachment reach when raised in dump ing position G Cab height H Digging depth I Loader bucket reach J Wheel base K Rear wheel base backhoe at...

Page 40: ...J 2200 mm 2200 mm 2200 mm K 1324 mm 1324 mm 1324 mm L 3040 mm 3040 mm 3040 mm M 7220 mm 7225 mm 7225 mm N 3935 mm 3935 mm 3935 mm P 2230 mm 2230 mm 2230 mm Q 2400 mm 2400 mm 2400 mm Performance Standa...

Page 41: ...mm Fork spacing Maximum centres 1773 mm Fork length 1026 mm Fork width 80 mm 580SR 580SR 590SR A Reach full height 2319 mm B Reach ground level 3186 mm C Lift height 2998 mm D Lift height 3458 mm 695...

Page 42: ...oaded B Bucket rotation C Operating height fully raised D Maximum height at full load E Reach from swing post F Reach from rear axle centre line G Maximum length of surface excavation H Maximum diggin...

Page 43: ...escopic dipper extended Swing arc 180 180 Maximum digging force dipper cylinder 3623 daN 2581 daN Maximum digging force bucket cylinder 5234 daN 5234 daN Lift capacity through dipper arc 1975 kg 1470...

Page 44: ...Operating height fully raised D Maximum height at full load E Reach from swing post F Reach from rear axle centre line G Maximum length of surface excavation H Maximum digging depth I Stabilizer sprea...

Page 45: ...lescopic dipper extended Swing arc 180 180 Maximum digging force dipper cylinder 3623 daN 2591 daN Maximum digging force bucket cylinder 5234 daN 5234 daN Lift capacity through dipper arc 2260 kg 1610...

Page 46: ...C Operating height fully raised D Maximum height at full load E Reach from swing post F Reach from rear axle centre line G Maximum length of surface excavation H Maximum digging depth I Stabilizer spr...

Page 47: ...lescopic dipper extended Swing arc 180 180 Maximum digging force dipper cylinder 3744 daN 2643 daN Maximum digging force bucket cylinder 5603 daN 5603 daN Lift capacity through dipper arc 2350 kg 1560...

Page 48: ...or a standard dip per and a telescopic dipper Standard dipper Telescopic dipper retracted Telescopic dipper extended Height Depth Dipper A Boom B Dipper A Boom B Dipper A Boom B m 610 5 4 1200 1120 92...

Page 49: ...r and a telescopic dipper Standard dipper Telescopic dipper retracted Telescopic dipper extended Height Depth Dipper A Boom B Dipper A Boom B Dipper A Boom B m 570 5 4 1120 1040 865 4 9 1520 1415 1510...

Page 50: ...per and a telescopic dipper Standard dipper Telescopic dipper retracted Telescopic dipper extended Height Depth Dipper A Boom B Dipper A Boom B Dipper A Boom B m 605 5 4 1075 990 905 4 9 1470 1365 146...

Page 51: ...SECTION 02 TECHNICAL SPECIFICATIONS 29 6 MAXIMUM LIFTING LOADS 6 1 LOADER ATTACHMENT MAXIMUM LIFTING LOAD TABLE 2WS 4WS www maskinisten net Copyright...

Page 52: ...30 SECTION 02 TECHNICAL SPECIFICATIONS 6 2 BACKHOE ATTACHMENT MAXIMUM LIFTING LOAD TABLE 2WS 4WS www maskinisten net Copyright...

Page 53: ...G 32 46 ALL 18 POWERSHIFT TRANSMISSION Akcela Trans XHD ATF DEXRON III ALL 14 FRONT AXLE 2WS Akcela Hy Tran Ultra MAT 3525 Differential 6 5 Wheel reduction gear each 0 7 FRONT AXLE 4WS Akcela Nexplore...

Page 54: ...32 SECTION 02 TECHNICAL SPECIFICATIONS NOTES www maskinisten net Copyright...

Page 55: ...4 INSPECTION 4 1 5 DISASSEMBLY AND ASSEMBLY 5 1 6 STALL TEST 5 1 7 FAULT FINDING 6 2 POWERSHIFT TORQUE CONVERTER 7 2 1 DESCRIPTION AND OPERATION 7 2 2 SPECIFICATIONS 8 2 3 OVERHAUL 8 2 4 INSPECTION 9...

Page 56: ...2 SECTION 17 TORQUE CONVERTERS www maskinisten net Copyright...

Page 57: ...shaft The torque multiplication gradually decreases as turbine speed approaches impeller speed and becomes 1 to 1 when the turbine is being driven at nine tenths impeller speed When the turbine 2 is r...

Page 58: ...used to clean the converter How ever if a commercial cleaner is not available the converter should be cleaned as outlined below Z Drain as much oil as possible from the hub of the converter by tilting...

Page 59: ...tly They can be checked by performing the Line Pres sure Test The engine and brakes must also be in good working order Z Check the coolant level in the radiator and the oil level in the transmission I...

Page 60: ...ar hydraulic clutch assembly is transmitting power even though the power revers ing lever is in neutral NOTE if the unit creeps forward and the gears clash the front clutch is at fault The rear clutch...

Page 61: ...This recirculation causes the converter to multiply torque The torque multiplication depends on the regularity of certain elements fan turbine and stator and on the output speed of the converter turb...

Page 62: ...n the stall test is cleaning and visual inspection A commercial torque convert er cleaner may be used to clean the converter How ever if a commercial cleaner is not available the converter should be c...

Page 63: ...s for cracks If the hub is worn or damaged and or the weld joints cracked a new converter must be installed A new drive plate should also be installed if it is warped 2 5 DISASSEMBLY AND ASSEMBLY DISA...

Page 64: ...SEMBLY Install the converter assembly on the input shaft Install the drive plates on the converter Install the drive plates screws and the lock washers and tighten the screws to the specified torque 4...

Page 65: ...gine 110 HP 1990 2140 rpm IMPORTANT to prevent the transmission from overheating do not allow the engine to operate at wide open throttle for more than fifteen seconds Z Allow the transmission oil to...

Page 66: ...engine power Replace the torque converter Replace the torque converter Replace the torque converter Check and correct output High stall speed Hydraulic clutch not applying or is slipping Low line pres...

Page 67: ...REMOVAL 31 1 11 DISASSEMBLY AND ASSEMBLY 32 1 12 FAULT FINDING 90 1 13 SPECIAL TOOLS 93 2 POWERSHIFT TRANSMISSION DANA T16000 94 2 1 SPECIFICATIONS 94 2 2 CONTROLS 95 2 3 LUBRICATION 105 2 4 PRESSURE...

Page 68: ...2 SECTION 21 TRANSMISSION www maskinisten net Copyright...

Page 69: ...clutch is not used with this transmission The transmission case serves as an oil tank for the torque converter and hydraulic clutch assemblies The transmission receives power from the engine 1 by a f...

Page 70: ...hims available 0 050 0 076 0 127 0 177 0 381 0 508 mm HYDRAULIC TESTS Tachometer setting 2000 rpm Test temperature oil 80 85 C Cold start valve for reference only 26 bar System pressure test 13 7 15 2...

Page 71: ...e regulator valve 46 to 60 Nm Cold start valve 46 to 60 Nm 4WD solenoid valve spool 20 to 27 Nm 4WD Solenoid coil retaining nut 5 4 Nm Control valve retaining screws 6 8 to 8 5 Nm 4WD hydraulic pipe c...

Page 72: ...tachment control lever this button is used to disengage the transmission in order to increase loader attachment power 5 ROLLER FOR THE PROPORTIONAL CON TROL OF LOADER BUCKET 4x1 6 POWERSHUTTLE TRANSMI...

Page 73: ...pushing button 2 placed on the gearshift lever 1 or by pushing button 5 placed on the loader control lever 3 S WARNING Always apply the parking brake whenever the ma chine is parked as the machine is...

Page 74: ...prevent inadvertent engagement of the transmission With this design the powershuttle lever moves through a T slot to the forward or re verse positions IMPORTANT when operating at low environmental tem...

Page 75: ...eed If another higher ratio is re quired repeat the procedure IMPORTANT to prevent possible damage to the transmission hydraulic clutches never use the dis connect switch for inching the machine forwa...

Page 76: ...en zone Once done operations may resume DIFFERENTIAL LOCK PEDAL MECHANICAL In conditions inducing wheel slip hold down the dif ferential lock pedal 1 with your heel until the differ ential lock engage...

Page 77: ...tial oil change and flush is recommended after the transmission is placed in actual service This change should be made at any time following 50 hours in service but should not exceed 100 hours When ch...

Page 78: ...12 SECTION 21 TRANSMISSION 1 5 TRANSMISSION OIL FLOW AND SUPPLY Pressure oil Disengaged Lubrication F29967 www maskinisten net Copyright...

Page 79: ...nted to the left of the trans mission viewed looking forward 5 FWD Low pressure system oil supply received from the filter at 14 bar and fed by external tube to rear of transmission to the FWD 6 Cold...

Page 80: ...D 18 litres 4WD 4 Oil Cooler Mounted below the engine coolant radiator 5 Oil pump suction port IN from the tank 6 Torque Converter oil OUT to oil cooler 7 Torque Converter pressure regulating valve re...

Page 81: ...sure protection valve 9 Torque converter pressure test point connected to test block 10 System pressure sequencing valve 11 Torque converter pressure regulating valve 12 Oil supply from pump to soleno...

Page 82: ...ck 4 Oil supply from the pump into the valve 5 Locating pin When the powershuttle lever in the cab is in neutral position the solenoid valve spool 1 will be static and oil 2 will not flow into either...

Page 83: ...When valve 2 moves it partially uncovers a port to the tank and also opens the control orifice within the valve Therefore a precisely metered flow of oil is fed to the pressure regulating feathering...

Page 84: ...5 System pressure sequencing valve 13 7 15 2 bar 6 Oil flow OUT to cooler 7 Oil OUT to cooler test port 6 5 bar 8 Front wheel drive test point 13 7 15 2 bar 9 Oil flow IN from cooler 10 Torque conver...

Page 85: ...draulic clutch 3 on the input shaft The input shaft then transmits power to the counter shaft forward gear and the countershaft in turn trans mits power to the output shaft Power flow for all four rev...

Page 86: ...20 SECTION 21 TRANSMISSION Input Intermediate Output F29980 www maskinisten net Copyright...

Page 87: ...SECTION 21 TRANSMISSION 21 NOTE 4WD shown www maskinisten net Copyright...

Page 88: ...22 SECTION 21 TRANSMISSION NOTE 4WD version shown www maskinisten net Copyright...

Page 89: ...SECTION 21 TRANSMISSION 23 1 8 TRANSMISSION 2WD COMPONENTS F27510 www maskinisten net Copyright...

Page 90: ...24 SECTION 21 TRANSMISSION F27511 www maskinisten net Copyright...

Page 91: ...4 Reverse idler gear 65 Input shaft assembly 66 Forward primary gear 67 Reverse primary gear 68 Clutch pack retaining clip 69 Clutch pack retaining plate 70 Clutch plate 71 Clutch plate friction 72 Ci...

Page 92: ...26 SECTION 21 TRANSMISSION 1 9 TRANSMISSION 4WD COMPONENTS F27512 www maskinisten net Copyright...

Page 93: ...SECTION 21 TRANSMISSION 27 www maskinisten net Copyright...

Page 94: ...primary gear 67 Reverse primary gear 68 Clutch pack retaining ring 69 Clutch pack retaining plate 70 Clutch plate steel 71 Clutch plate friction 72 Circlip 73 Spring retainer 74 Piston return spring...

Page 95: ...Expansion plug 150 Brake caliper nut 151 Pump mounting stud 152 Oil filter housing 153 Filter housing gasket 154 Screw 155 O ring 156 Cold start spring 157 Ball 158 Adjuster screw 160 Adjuster screw...

Page 96: ...t seal 3 Solenoid 4 Washer 5 Solenoid body 6 Guide 7 Spring 8 Solenoid pin 9 Seal 10 Support body solenoid 11 End cap 12 Circlip 13 Clutch fill metering valve 14 Spring 15 Spool 16 Piston clutch fill...

Page 97: ...he starter motor 1 Engine timing tab 2 Torque converter back plate attaching bolts through the starter motor aperture 1 Bell housing attachment bolts 3 IMPORTANT prior to positioning the transmission...

Page 98: ...table bench For convenience the bench top should have a hole in it to accommodate the input shaft and pump Re move 3 screws and withdraw the gearshift lever as sembly Remove the plastic plugs and 4 ca...

Page 99: ...33 Remove the pressure regulator valve Remove the cold start housing the spring and the ball Remove the temperature sender Remove the bolt the washer and the O ring and withdraw the output yoke www ma...

Page 100: ...ear transmission case Lever slots are provided to assist removal NOTE the bearing cones and shims may fall from the rear case during removal IMPORTANT for proper reassembly take note and mark which be...

Page 101: ...ass plug the spring and the ball Ensure both synchronizers are in the neutral posi tion then remove the 1st 2nd shift fork screw Withdraw the 1st 2nd shift rod from the housing Then using a magnetic p...

Page 102: ...e the 3rd 4th shift rail replace the detent plug as the ball and spring may shoot out and cause injury Turn the 3rd 4th shift rod through 90 and withdraw from the housing Remove the detent plug the in...

Page 103: ...he 1st 2nd and 3rd 4th shift forks Remove the output shaft front assembly Remove the 4th gear lock out screw if fitted Remove 2 screws and withdraw the strainer cover the O ring the spacer and the str...

Page 104: ...remove and discard the oil fil ter Remove 2 bolts and take of the oil filter housing and the gasket Remove the 4WD solenoid coil and the retaining nut on 4WD models only Remove the 4WD solenoid spool...

Page 105: ...SMISSION 39 Remove and discard the expansion plug from the shimming access hole Invert the case Remove 4 screws and copper wash ers then withdraw the pump assembly and the seal ing ring www maskiniste...

Page 106: ...ASSEMBLY Position the shaft in a soft jawed vice as shown Remove and discard the 3 sealing rings Using the appropriate bearing puller 380002683 re move the rear bearing Remove the thrust washer and ne...

Page 107: ...SMISSION 41 Remove the reverse primary gear Remove the bearing the spacer the bearing and the thrust washer Remove the clutch pack retaining ring Remove the clutch pack retaining plate www maskinisten...

Page 108: ...he clutch pack Using the appropriate tool 380002689 compress the piston spring and release the circlip Replace the spring the retainer and the circlip Using pliers as shown pull the piston out of the...

Page 109: ...NSMISSION 43 Invert the shaft and remove the sealing ring Repeat steps described above to dismantle the for ward clutch pack Remove and discard the piston sealing rings and the O rings www maskinisten...

Page 110: ...assembly bend the inner sealing ring into a heart shape as shown Using transmission fluid to lubricate the seals push the piston into the drum Replace the spring the retainer and the circlip Using th...

Page 111: ...place the clutch pack retaining plate and refit the retaining clip Replace the thrust washer the bearing the spacer and the bearing Line up the clutch plate splines and replace the pri mary gear Remov...

Page 112: ...Invert the shaft and repeat previous operation Then fit a new sealing ring as shown Finally fit 3 new sealing rings to the rear of the shaft as shown To avoid damage the sealing rings should be left o...

Page 113: ...RSHAFT The countershaft assembly Using the appropriate bearing pullers 380002691 and 380002687 remove the countershaft front and the rear bearings Using an appropriately sized tube replace the coun te...

Page 114: ...MBLY OF THE REVERSE IDLER SHAFT The reverse idler assembly Using the appropriate bearing puller 380002683 re move the front and the rear bearings Using an appropriately sized tube replace the front an...

Page 115: ...SEMBLY Position the shaft assembly in a soft jawed vice as shown Using the appropriate bearing puller 380002686 re move the front bearing Refit the 4th gear and the thrust washer Remove the 3rd 4th sy...

Page 116: ...rclip and the synchro hub Remove the 3rd gear Invert the shaft and using the appropriate bearing puller 380002687 remove the rear bearing Remove the 4WD gear on 2WD models a spacer is fitted instead o...

Page 117: ...ove the 1st gear Remove the needle bearings and the spacer Remove the 1st 2nd synchronizer assembly Using a suitable bearing puller or press Remove the bearing sleeve the synchro hub and the 2nd gear...

Page 118: ...52 SECTION 21 TRANSMISSION Remove the bearing sleeve the synchro hub and the 2nd gear www maskinisten net Copyright...

Page 119: ...SSEMBLY Replace the 2nd gear and the synchro hub Using an appropriately sized tube refit the 1st gear bearing sleeve Replace the 1st 2nd synchronizer assembly Replace the 1st gear needle bearings and...

Page 120: ...equivalent NOTE assemble the gear with the splined bushing against the 1st speed gear on 2WD models a spac er is fitted instead of the gear Using an appropriately sized tube refit the rear bear ing I...

Page 121: ...SECTION 21 TRANSMISSION 55 Refit the 3rd 4th synchronizer assembly Refit the 4th gear and the thrust washer Using an appropriately sized tube replace the front bearing www maskinisten net Copyright...

Page 122: ...4WD DISASSEMBLY The hydraulic dog clutch 4WD assembly Position the shaft in a soft jawed vice and remove the sealing ring Using the appropriate bearing puller 380002685 re move the rear bearing Remove...

Page 123: ...emove the two needle bearings and the spacer Invert the shaft and using the appropriate bearing puller 380002685 remove the front bearing Using the appropriate tool 380002692 compress the spring and r...

Page 124: ...he spring the retainer and the circlip Remove the piston drum assembly Remove the piston seal and the O ring from the shaft and discard Remove and discard the piston seal and the O ring from the pisto...

Page 125: ...ring to the shaft Fit a new O ring and sealing ring into the piston Bend the sealing ring into a heart shape as shown to assist assembly Lubricate the seals with a light grease and refit the piston t...

Page 126: ...tool 80002692 compress the spring and retainer and refit the circlip Using an appropriately sized tube refit the front bear ing Invert the shaft and refit the two needle bearings and spacer as shown R...

Page 127: ...ce the thrust washer Using an appropriately sized tube replace the rear bearing Fit a new seal ring To avoid damage the sealing ring should be left off until all shimming operations have been complete...

Page 128: ...ON 21 TRANSMISSION PERMANENT 4WD SHAFT ASSEMBLY The permanent 4WD shaft Using the appropriate bearing puller 380002685 re move the front and the rear bearings Remove the 4WD gear www maskinisten net C...

Page 129: ...MISSION 63 PERMANENT 4WD SHAFT ASSEMBLY Replace the 4WD gear using Loctite 649 or equiva lent on the shaft splines Then using a suitably sized tube refit the front and the rear bearings www maskiniste...

Page 130: ...ydraulic multiplate clutch 4WD shaft assembly Mount the shaft assembly in a suitable soft jawed vice and remove the rear sealing ring Using the appropriate bearing puller 380002685 re move the rear be...

Page 131: ...CTION 21 TRANSMISSION 65 Remove the 4WD gear Remove the needle bearings and the spacer Remove the needle bearing and the thrust washer Remove the clutch pack retaining clip www maskinisten net Copyrig...

Page 132: ...Remove the clutch pack retaining plate Remove the clutch pack Using the appropriate tool 380002690 compress the piston return spring and release the circlip Remove the clip retainer and the spring www...

Page 133: ...21 TRANSMISSION 67 Remove the piston from the drum Remove and discard the piston sealing rings Invert the shaft and remove the front bearing using the appropriate tool 380002685 www maskinisten net Co...

Page 134: ...to assembly NOTE the outer seal must be fitted with the open edge facing away from the clutch pack Using the appropriate tool 380002684 compress the piston sealing rings The seals should be left in th...

Page 135: ...circlip into its groove Replace an externally splined plain disc then an in ternally splined friction disc alternately until 8 plain discs and 8 friction discs have been fitted Replace the retaining...

Page 136: ...21 TRANSMISSION Refit the 4WD gear Refit the needle bearings and the spacer Refit the needle bearing and the thrust washer Using an appropriately sized tube refit the rear bear ing www maskinisten net...

Page 137: ...1 TRANSMISSION 71 Refit a new sealing ring and lubricate with a light grease To avoid damage the sealing ring should be left off until all shimming operations have been com pleted www maskinisten net...

Page 138: ...dividual components of the oil pump are non serv iceable The pump may however be stripped for cleaning and examination purposes View showing a dismantled pump assembly The pump oil seal may be replace...

Page 139: ...oids individual parts are non serviceable It may however be dismantled for cleaning and examination The valve fitted may be either the modulated type or the non modulated type The retaining nut coil a...

Page 140: ...assembly apart Before re assembly remove all traces of old sealant from the joint faces Apply a bead of RTV joint compound Loctite 5900 to the sealing face Lubricate the ball seating with a light grea...

Page 141: ...hould not be used Position the front case as shown and using a suita bly sized tube fit a new output shaft oil seal to a depth of 6 mm below the housing face Fill the seal lip with grease on 4WD model...

Page 142: ...ring cups if pre viously removed Using a suitable tool push the inner detent spring and ball into the case and secure in place with a dummy plug as shown Dummy plug in place Replace the countershaft a...

Page 143: ...dum my plug as it enters the bore NOTE check that the inner detent spring and ball have not become displaced and remove the loose dummy plug from the case sump Push the interlock ball into the detent...

Page 144: ...shaft front and rear seals with a light grease and refit the shaft assembly into the case Rear case with all shaft assemblies fitted Position the rear case as shown and using a suitably sized tube fi...

Page 145: ...lts When fitting the rear case be careful to avoid dam aging the input shaft sealing rings Position a D T I on the end of the input shaft as shown and using a suitable pry bar through the side access...

Page 146: ...te the end float Attach a suitable shimming tool 380002693 to the end of the 4WD shaft Position a D T I as shown and using a pry bar lift the shaft then measure and note the end float on 4WD models on...

Page 147: ...torque of 45 64 Nm Replace the shaft end plug and O ring assemblies Note the special breather plug is fitted in the reverse idler position Tighten to a torque of 41 54 Nm Fit a new expansion plug to t...

Page 148: ...start ball the spring and the housing Then tighten to a torque of 46 60 Nm Lubricate the seals with transmission fluid then refit the pressure regulator valve and tighten to a torque of 46 60 Nm Lubri...

Page 149: ...ews to a torque of 6 8 to 8 5 Nm Refit the 4 plastic caps to the capscrew holes NOTE the valve can only be fitted one way round as it is located by a small dowel pin Refit the strainer the spacer the...

Page 150: ...itional sealing plug may be fitted Apply a bead of RTV joint compound Loctite 5900 to the gear case Refit the gear lever assembly and tighten the three bolts to a torque of 16 24 Nm Refit the filter h...

Page 151: ...tact Slightly lubricate the seals and refit the 4WD sole noid valve spool on 4WD models only Tighten to a torque of 20 27 Nm Remove the 4WD solenoid coil and the nut on 4WD models only Tighten to a to...

Page 152: ...more than 1 bar lower than the oil pump pressure Oil pump pressure test port Pressure should be 13 5 to 15 5 bar at maximum engine speed Ap proximately 2500 rpm Reverse clutch pressure test point Pre...

Page 153: ...lowed These checks should be carried out while the transmission is still in the vehicle so that true op erating conditions are created Pressure checks are essential since a failure in the hydraulic sy...

Page 154: ...e locknuts against mounting surface to 155 Nm B Adjust this nut until pads are in contact with the brake pads Then loosen 1 2 turn Finally torque outer locknut to 60 70 Nm IMPORTANT BRAKE PAD the mini...

Page 155: ...SECTION 21 TRANSMISSION 89 Brake pad replacement Remove the retaining spring clip Withdraw the friction pads www maskinisten net Copyright...

Page 156: ...rts No drive from 4WD 4WD solenoid valve or coil not operating Mechanical failure in transmission Low 4WD clutch pack pressure Worn 4WD clutch pack Transmission overheating Oil level too high or low C...

Page 157: ...orward reverse clutch pack pressure Pressure relief solenoid valve faulty Converter pressure low Converter relief valve faulty Leak in converter oil cooler or connection hoses Very hot oil Converter p...

Page 158: ...ion Shift rods worn or bent Shift forks worn loose or twisted Synchronizer assemblies worn or damaged Clutch pack not releasing due to mechanical fault Clutch pack not releasing due to hydraulic fault...

Page 159: ...t and of the front bearing of the coaxial input shaft 380002686 Output shaft front bearing removal collect 380002687 C shaft and output shaft rear bearing removal collect 380002689 Input shaft spring...

Page 160: ...Conform SAE J1019 and SAE J517 100RI Weight 290 kg BOLT TORQUES Output flanges 339 407 Nm Filter torque 30 38 Nm Control valve connector nut to cover 6 8 Nm ELECTRICAL SPECIFICATIONS Solenoid coil re...

Page 161: ...will dis engage when wheel torque equalises or the foot brakes are applied 3 LOADER ATTACHMENT CONTROL LEVER 4 TRANSMISSION DISCONNECT BUTTON 5 ROLLER FOR THE PROPORTIONAL CON TROL OF LOADER BUCKET 4...

Page 162: ...96 SECTION 21 TRANSMISSION Powershift 4x2 EGS transmission display Forward travel selection 4 www maskinisten net Copyright...

Page 163: ...SECTION 21 TRANSMISSION 97 Powershift 4x2 EGS transmission display Reverse travel selection 5 www maskinisten net Copyright...

Page 164: ...ode LED Letter T Self diagnostic mode Used in self diagnostic test mode and will illuminate during self test NOTE in the event of a fault the light will flash Contact your Authorized Dealer for assist...

Page 165: ...fault is detected at power up the limp home func tion is automatically selected IMPORTANT if limp home is active only 1st and 2nd gear will be selectable but without modulation The limp home function...

Page 166: ...ting forward travel To select forward travel push the lever away from you and the F LED will illuminate green NOTE when forward is selected you will not be giv en any indication of gear selected only...

Page 167: ...eep slope select the second gear upshifting only when it is safe to do so You cannot downshift to reduce speed if the machine speed is above 15 km h Downshifting to the desired gear is achieved by twi...

Page 168: ...ected downshift en gages but momentum forward remains until the speed lowers sufficiently to allow downshift to take place when reverse is achieved in 2nd gear RESPONSE 2 if the machine speed in forwa...

Page 169: ...erator pedal Kickdown The kickdown facility 2nd to 1st gear only on this transmission increases torque instantly to the driving wheels and hence pushing power For example when the loader is pushing i...

Page 170: ...d available and at which speed an automatic shift takes place in each gear Automatic upshift speed Automatic downshift speed As it can be seen when downshifting from the 4th gear at a maximum speed of...

Page 171: ...spheric conditions will cause accel erated deterioration and contamination For extreme conditions judgement must be used to determine the required change intervals Z Every 1000 hours change oil filter...

Page 172: ...rnal leakage 1 5 3 0 l min for each clutch Maximum total leakage 6 8 l min clutch leakage range converter leak valve leak without discon nect clutch Safety valve cracking pressure 9 5 10 5 bar To cool...

Page 173: ...cooler 12 Pressure check port 4WD 18 9 27 5 bar 13 Pressure check port regulator pressure 19 6 23 7 bar 14 Filter plug M22 x 1 5 E Bottom view F Right side view 15 Temperature check port converter ou...

Page 174: ...m cooler to transmission lube distributor COOLING SYSTEM SPECIFICATIONS Suitable for operation from ambient to 120 C con tinuous operating temperature Must withstand a 20 bar continuous pressure and a...

Page 175: ...r 18 Accumulator 19 Pressure booster 0 5 5 to 0 20 bar 20 Electronic controlled modulation valve 5 5 to 0 bar 21 Modulated pressure 0 to 20 bar 22 Clutch pressure 20 bar 23 Solenoid N forward 24 Solen...

Page 176: ...ssure regulating valve maintains pressure for the control valve and clutches at 20 bar Excess oil volume is bled off into the converter system A safety valve is fitted between the pressure regulator a...

Page 177: ...SSION 111 Basically the transmission is composed of five main assemblies The converter and pump drive section The input or directional clutches The range clutches The output section F27723 www maskini...

Page 178: ...o take the fluid which is exhausting from the inner portion of the turbine and change its direction to allow correct entry for recirculation into the impeller element This recirculation causes the con...

Page 179: ...es to the select ed clutch shafts Oil seals are located on the clutch shafts These rings direct the oil through a drilled passage in the shaft to the desired clutch Pressure of the oil forces the pist...

Page 180: ...UT SECTION With a range clutch engaged power is finally trans mitted to the output shafts The transmission can have an upper output or lower output at the rear side of the unit and a lower output at t...

Page 181: ...tronic modulation valve and the booster is an accumulator to damper any hydraulic vibration When forward is selected the electronic modulation valve and the forward solenoid are activated The pilot pr...

Page 182: ...the front lower output disconnect clutch If the solenoid is not activated full oil pressure is fed through the disconnect shift spool to the dis connect clutch If the solenoid is activated pilot pres...

Page 183: ...SECTION 21 TRANSMISSION 117 2 8 POWER FLOWS 1st speed forward 2nd speed forward 3rd speed forward 4th speed forward F27730 F27729 F27132 F27731 www maskinisten net Copyright...

Page 184: ...118 SECTION 21 TRANSMISSION 1st speed reverse 2nd speed reverse F27734 F27733 www maskinisten net Copyright...

Page 185: ...tral reverse shift spool 9 Pressure booster 0 20 bar 10 Neutral forward solenoid 11 High low shift spool 12 High low solenoid 13 Neutral reverse solenoid 14 1st gear clutch 15 Accumulator 16 Electroni...

Page 186: ...4 3 bar 7 System pressure test port 20 bar 8 Oil flow to control valve 9 System pressure regulating valve 20 bar 10 Torque converter system relief valve 10 bar 11 Converter system pressure test port...

Page 187: ...pass valve 4 3 bar 7 System pressure test port 20 bar 8 System pressure regulating valve 20 bar 9 Oil flow to converter 10 Oil flow to shift spools 11 Pressure reducing valve 5 5 bar 12 2nd 1st Solen...

Page 188: ...re booster so that a curve of 0 20 bar is avail able for the directional clutches Between the modulation valve and the booster is accumulator to dampen any hydraulic vibration Suction oil High pressur...

Page 189: ...valve Z The modulation pressure curve is multiplied by 4 in the pressure booster so that a curve of 0 20 bar is avail able for the directional clutch Between the modulation valve and the booster is ac...

Page 190: ...to the pressure booster valve Z The modulation pressure curve is multiplied by 4 in the pressure booster so that a curve of 0 20 bar is avail able for the directional clutches Between the modulation v...

Page 191: ...rrent from the microprocessor pilot pressure gradually increases act ing on the boost valve and it multiplies pilot pressure Z The oil from the boost valve is modulated allowing a steady increase of p...

Page 192: ...126 SECTION 21 TRANSMISSION Suction oil High pressure oil Torque Converter and Lubrication Oil Return to oil tank Pilot pressure Modulated pilot oil F29992 www maskinisten net Copyright...

Page 193: ...flow on to the forward high shift spool Z The modulation valve has a reducing current from the microprocessor pilot pressure gradually increases act ing on the boost valve and it multiplies pilot pre...

Page 194: ...128 SECTION 21 TRANSMISSION Suction oil High pressure oil Torque Converter and Lubrication Oil Return to oil tank Pilot pressure Modulated pilot oil F29993 www maskinisten net Copyright...

Page 195: ...a reducing current from the microprocessor pilot pressure gradually increases act ing on the boost valve and it multiplies pilot pressure Z The oil from the boost valve is modulated allowing a steady...

Page 196: ...130 SECTION 21 TRANSMISSION Suction oil High pressure oil Torque Converter and Lubrication Oil Return to oil tank Pilot pressure Modulated pilot oil F29994 www maskinisten net Copyright...

Page 197: ...at 20 bar Excess oil flow is bled to the converter system which is protected by a 10 bar safety valve Oil enters the converter through the converter blade cavity and exits in the passage between the t...

Page 198: ...132 SECTION 21 TRANSMISSION 2 9 GEAR AND CLUTCH LAY OUT Forward low Forward high Reverse and 1st 2nd Disconnect Input shaft t u O n I t u O F27735 www maskinisten net Copyright...

Page 199: ...erant reclaim system is to be used Engine Transmission removal from the ma chine does not require the system to be discharged Remove the condenser from the front radiator and place the condenser to on...

Page 200: ...l pipes attached Check that the oil pump drive shaft does not slide out with the pump 23 Check return from steering motor is on the out side of transmission oil level tube 24 With the engine supported...

Page 201: ...engine crankshaft using a torque bar to ex pose in turn each attaching bolt hole of the flywheel through the flexi plate and refit all of the bolts Hoist the engine transmission assembly back into the...

Page 202: ...to flywheel housing screws Tighten screws to speci fied torque Remove transmission to engine guide studs Install remaining screws and tighten to speci fied torque Remove drive plate locating stud Inst...

Page 203: ...SECTION 21 TRANSMISSION 137 2 11 TRANSMISSION COMPONENTS CONVERTER HOUSING AND TRANSMISSION www maskinisten net Copyright...

Page 204: ...ptor 1 21 Filter adaptor 1 22 Lock washer filter adaptor screw 3 23 Screw filter adaptor 3 24 Assembly filter 1 25 Oil seal output shaft front 1 26 Screw converter housing to transmission case 1 27 Lo...

Page 205: ...er housing to transmission case 4 48 Case transmission 1 49 O ring 1 50 Plug 1 51 Plug 11 52 O ring 11 53 Seal upper output 1 54 Screw converter housing to transmission case 5 55 Lock washer converter...

Page 206: ...140 SECTION 21 TRANSMISSION INPUT SHAFT TORQUE CONVERTER PUMP DRIVE INTERNAL CHARGING PUMP AND DRIVE PLATE www maskinisten net Copyright...

Page 207: ...ump 1 12 O ring charging pump 1 13 Ring piston 1 14 Bearing input shaft front 1 15 Snap ring 1 16 Snap ring 8 17 Gear forward low and reverse drive 9 18 Snap ring 1 19 Input shaft 1 20 Snap ring 1 21...

Page 208: ...SECTION 21 TRANSMISSION 19 20 21 22 23 24 25 26 27 28 29 30 32 31 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 2 3 5 4 6 8 7 9 10 13 12 11 14 15 16 1 17 18 F27746 www maskinisten net Copyrig...

Page 209: ...1 19 Retaining ring 1 20 Retainer spring 1 21 Spring piston return 1 22 Plate spring clutch piston wear 1 23 Assembly clutch piston and seals 1 24 Seal clutch piston outer 1 25 Seal clutch piston inne...

Page 210: ...washer 1 43 Thrust bearing 1 44 Bearing needle 1 45 Gear forward high clutch 1 46 Bearing needle 1 47 Thrust bearing 1 48 Thrust washer 1 49 Bearing rear forward low forward high shaft 1 50 Ring pisto...

Page 211: ...RANSMISSION 145 REVERSE 1ST SHAFT AND GEARS 19 20 21 22 23 24 25 26 27 28 29 30 32 47 46 44 45 43 42 41 40 39 38 37 36 33 34 35 1 2 3 4 5 6 8 7 9 10 11 12 14 13 15 16 17 18 31 F27747 www maskinisten n...

Page 212: ...8 Disc outer half 1 19 Retaining ring 1 20 Retainer spring 1 21 Spring piston return 1 22 Plate spring clutch piston wear 1 23 Assembly clutch piston and seals 1 24 Seal clutch piston outer 1 25 Seal...

Page 213: ...g ring clutch gear bearing 1 42 Gear 1st clutch 1 43 Retaining ring clutch gear bearing 1 44 Bearing clutch gear 1 45 Snap ring 1 46 Bearing rear reverse 1st shaft 1 47 Ring piston 3 ITEM DESCRIPTION...

Page 214: ...148 SECTION 21 TRANSMISSION 2ND SHAFT 16 25 24 26 27 28 29 30 31 23 22 21 20 19 18 17 1 2 3 4 5 6 7 8 9 10 11 12 13 15 14 F27748 www maskinisten net Copyright...

Page 215: ...ing 1 12 Disc outer half 1 13 Disc outer 8 14 Disc inner 9 15 Disc outer half 1 16 Retaining ring 1 17 Retainer spring 1 18 Spring clutch piston return 1 19 Plate spring clutch piston wear 1 20 Assemb...

Page 216: ...150 SECTION 21 TRANSMISSION OUTPUT SHAFT WITH INTERNAL DISCONNECT 15 14 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 2 3 4 5 6 7 8 9 10 11 13 12 F27749 www maskinisten net Copyright...

Page 217: ...clutch disc backing 1 14 Disc outer half 1 15 Disc outer 11 16 Disc inner 12 17 Disc outer half 1 18 Retaining ring 1 19 Retainer spring 1 20 Spring piston return 1 21 Plate spring clutch piston wear...

Page 218: ...t brake mounting screw 2 4 Nut jam adjustment 1 5 Nut adjustment 1 6 Washer hardened 1 7 Washer stainless steel 1 8 Thrust washer 1 9 Lever 1 10 Boot 1 11 Cam 1 12 Oil seal 1 13 Ball bearing 3 14 Plas...

Page 219: ...ECTION 21 TRANSMISSION 153 16 Torque plate front 1 17 Pads assembly 2 18 Torque plate rear 1 19 Sleeve mounting 2 20 Adjuster screw 1 21 Spring 1 ITEM DESCRIPTION QUANTITY www maskinisten net Copyrigh...

Page 220: ...M DESCRIPTION QUANTITY 1 Control valve assembly 1 2 Control valve mounting screws 17 3 Control valve protection cover gasket 1 4 Control valve protection cover 1 5 Protection cover screw 20 6 Air brea...

Page 221: ...NS 1 Add some grease to O ring before assembly 2 Add some grease to piston rings before assem bly slots of the piston rings are not allowed to pass bores in housings 3 15 12 2 11 3 2 13 10 9 15 5 2 3...

Page 222: ...mm for carbon plates max clearance 2 76 mm for carbon plates 8 Disconnect clutch 12 separator plates 11 fric tion plates and two 1 side friction plates Assembly see 6 Clearance min clearance 3 66 mm...

Page 223: ...ON 21 TRANSMISSION 157 TRANSMISSION DISASSEMBLY Remove the oil filter Remove the filter adapter screws Remove the filter adapter with the O ring Remove the drive plate screws www maskinisten net Copyr...

Page 224: ...158 SECTION 21 TRANSMISSION Remove the drive plates Remove the torque converter assy Remove the charging pump screws Use a bearing puller to remove the charging pump www maskinisten net Copyright...

Page 225: ...ON 159 Remove the charging pump assy remove the O ring Remove the parking brake mounting screws Remove the parking brake assy Remove the upper output nut the washer the O ring and the flange www maski...

Page 226: ...SMISSION Remove the air breather Remove the control valve protection cover mounting screws Remove the wiring connector mounting nut Remove the control valve protection cover and the gasket www maskini...

Page 227: ...ol valve mounting screws Remove the control valve assy remove the by pass valve spool and the spring in the meantime Remove the auxiliary pump hole cover screws Remove the auxiliary pump hole cover an...

Page 228: ...haft and the bearing assy Remove the pump drive shaft and the bearing assy Remove the upper output nut the washer the O ring and the flange Remove the converter housing to the transmission case screws...

Page 229: ...ut shaft rear bearing retaining ring Hold snap ring open Tap on the output shaft and transmission case to remove the case from the converter housing Lift transmission case from converter housing using...

Page 230: ...ve the transmission case to converter housing gasket Remove the output shaft sealing rings Remove the output shaft rear bearing retaining ring Use bearing puller to remove the output shaft rear bearin...

Page 231: ...ION 165 Output shaft rear bearing removed Using bearing puller to remove the 2nd shaft rear bearing 2nd shaft rear bearing removed Using bearing puller to remove the input shaft rear bearing www maski...

Page 232: ...ON Input shaft rear bearing removed Remove the reverse and 1st shaft sealing rings Using bearing puller to remove the reverse and 1st shaft rear bearing Reverse and 1st shaft rear bearing removed www...

Page 233: ...shaft sealing rings Using bearing puller to remove the forward low and the forward high shaft rear bearing Forward the low and forward high shaft rear bearing removed Use bearing puller to remove the...

Page 234: ...e the baffle plate screws remove the baffle plates Remove the oil baffle to the converter housing screws do not remove the oil baffle from the output shaft Remove the output shaft the 2nd shaft and th...

Page 235: ...MISSION 169 Loosen the suction tube retainer screw Remove suction tube retainer screw and lock washer Remove the suction tube retainer ring Remove the suction tube O ring and the washer www maskiniste...

Page 236: ...the output shaft front bearing retainer ring Remove the output shaft front assembly Remove the input shaft the reverse and the forward shaft at the same time Remove the by pass plug the spring and the...

Page 237: ...SECTION 21 TRANSMISSION 171 Remove the by pass plug the spring and the ball www maskinisten net Copyright...

Page 238: ...ISSION FORWARD HIGH CLUTCH DISASSEMBLY Remove the clutch shaft sealing rings Remove the thrust washer and the thrust bearing Remove the clutch gear outer needle bearing Remove the clutch gear www mask...

Page 239: ...TRANSMISSION 173 Remove the clutch gear inner needle bearing Remove the thrust washer and the thrust bearing Remove the backing plate retainer ring Remove the clutch plate spacer www maskinisten net...

Page 240: ...174 SECTION 21 TRANSMISSION Remove the clutch disc backing plate Remove the one outer half disc Remove the inner and the outer discs Remove the one outer half disc www maskinisten net Copyright...

Page 241: ...NSMISSION 175 Compress the spring to remove the spring retainer snap ring Remove the spring retainer snap ring Remove the clutch spring spacer Remove the clutch piston spring retainer www maskinisten...

Page 242: ...176 SECTION 21 TRANSMISSION Remove the clutch piston spring Remove the clutch piston wear plate Remove the clutch piston assy www maskinisten net Copyright...

Page 243: ...CH DISASSEMBLY Use bearing puller to remove the front bearing and gear Front bearing and gear removed Remove the gear retaining ring Use a bearing puller to remove the clutch gear and the clutch gear...

Page 244: ...178 SECTION 21 TRANSMISSION Clutch the gear and the outer bearing removed Remove the spacer snap ring Remove the spacer Remove the backing plate retainer ring www maskinisten net Copyright...

Page 245: ...1 TRANSMISSION 179 Remove the clutch disc backing plate Use bearing puller to remove the clutch gear inner bearing Clutch gear inner bearing removed Remove the one outer half disc www maskinisten net...

Page 246: ...NSMISSION Remove the inner and the outer discs Remove the one outer half disc Remove the clutch gear inner bearing locating ring Compress the spring to remove the spring retainer snap ring www maskini...

Page 247: ...CTION 21 TRANSMISSION 181 Remove the spring retainer snap ring Remove the clutch piston spring retainer Remove the clutch piston spring Remove the clutch piston wear plate www maskinisten net Copyrigh...

Page 248: ...182 SECTION 21 TRANSMISSION Remove the clutch piston assy www maskinisten net Copyright...

Page 249: ...piston while holding a round object against the new sealing ring Rotate piston until sealing ring is flush with out er diameter of the piston Install the clutch piston inner seal Install the clutch pi...

Page 250: ...g Use a sleeve with the proper diameter to fit over shaft and against retainer ring A sharp blow with a soft hammer will compress the spring and seat re tainer ring Be sure ring is in full position in...

Page 251: ...nate friction and steel discs until the proper amount of discs are installed First and last discs are steel Install one outer half disc with friction material down Install the backing plate Install th...

Page 252: ...186 SECTION 21 TRANSMISSION Install the spacer Install the spacer snap ring Install the inner bearing snap ring Install the clutch gear inner bearing www maskinisten net Copyright...

Page 253: ...sealing ring Install the clutch gear in the clutch drum Align splines on clutch gear with internal teeth of steel discs Do not force this op eration Gear splines must be in full position with in terna...

Page 254: ...21 TRANSMISSION Tap the outer bearing into the place Install the outer bearing snap ring Warm the gear to 150 C install the gear Warm the front bearing to 120 C install the bearing www maskinisten ne...

Page 255: ...iston while holding a round object against the new sealing ring Rotate piston until sealing ring is flush with out er diameter of the piston Install the piston inner seal and install the clutch pis to...

Page 256: ...er spacer Install the clutch spring retainer snap ring Use a sleeve with the proper diameter to fit over shaft and against retainer ring A sharp blow with a soft hammer will compress the spring and se...

Page 257: ...rial away from the piston Install one steel disc Alternate friction and steel discs until the proper amount of discs are installed first and last discs are steel Install one outer half disc with frict...

Page 258: ...RANSMISSION Install the backing plate spacer Install the backing plate spacer retainer ring Install the thrust washer and the thrust bearing Install the clutch gear inner needle bearing www maskiniste...

Page 259: ...ith internal teeth of steel discs Do not force this operation Gear splines must be in full position with internal teeth of all inner discs Install the clutch gear outer needle bearing Install the thru...

Page 260: ...EMBLY Remove the clutch shaft sealing rings Remove the clutch gear bearing retaining ring Use a bearing puller to remove the clutch gear and the clutch gear outer bearing Clutch the gear and the outer...

Page 261: ...ON 21 TRANSMISSION 195 Remove the backing plate retainer ring Remove the backing plate Remove the modulation spring Use bearing puller to remove the clutch gear inner bearing www maskinisten net Copyr...

Page 262: ...196 SECTION 21 TRANSMISSION Clutch gear inner bearing removed Remove the one outer half disc Remove the inner and the outer discs Remove the one outer half disc www maskinisten net Copyright...

Page 263: ...he clutch piston belleville washer spring Remove spring snap ring NOTE force of disc spring is 3280N Spring retainer ring removed Remove the disc belleville washer spring Remove the clutch piston wear...

Page 264: ...198 SECTION 21 TRANSMISSION Remove the clutch piston assy www maskinisten net Copyright...

Page 265: ...LY Use a bearing puller to remove the gear and the front bearing Gear and front bearing removed Remove the clutch gear bearing retaining ring Use a bearing puller to remove the clutch gear and the clu...

Page 266: ...200 SECTION 21 TRANSMISSION Clutch the gear and the outer bearing removed Remove the spacer snap ring Remove the spacer Remove the backing plate retainer ring www maskinisten net Copyright...

Page 267: ...1 TRANSMISSION 201 Remove the clutch disc backing plate Use bearing puller to remove the clutch gear inner bearing Clutch gear inner bearing removed Remove the one outer half disc www maskinisten net...

Page 268: ...21 TRANSMISSION Remove the inner and the outer discs Remove the one outer half disc Remove the inner bearing locating ring Compress the spring to remove the spring retainer snap ring www maskinisten n...

Page 269: ...CTION 21 TRANSMISSION 203 Remove the spring retainer snap ring Remove the clutch piston spring retainer Remove the clutch piston spring Remove the clutch piston wear plate www maskinisten net Copyrigh...

Page 270: ...204 SECTION 21 TRANSMISSION Remove the clutch piston assy www maskinisten net Copyright...

Page 271: ...rotating piston while holding a round object against the new sealing ring Rotate piston until sealing ring is flush with out er diameter of the piston Install the clutch piston inner seal Install the...

Page 272: ...g Use a sleeve with the proper diameter to fit over shaft and against retainer ring A sharp blow with a soft hammer will compress the spring and seat re tainer ring Be sure ring is in full position in...

Page 273: ...nate friction and steel discs until the proper amount of discs are installed First and last discs are steel Install one outer half disc with friction material down Install the backing plate Install th...

Page 274: ...208 SECTION 21 TRANSMISSION Install the spacer Install the spacer snap ring Install the inner bearing snap ring Install the clutch gear inner bearing www maskinisten net Copyright...

Page 275: ...ng ring Install the clutch gear in the clutch drum Align splines on clutch gear with internal teeth of steel discs Do not force this op eration Gear splines must be in full position with in ternal tee...

Page 276: ...21 TRANSMISSION Tap the outer bearing into the place Install the outer bearing snap ring Warm the gear to 150 C install the gear Warm the front bearing to 120 C install the bearing www maskinisten ne...

Page 277: ...ainst the new sealing ring Rotate piston until sealing ring is flush with out er diameter of the piston Install the piston inner seal Install the clutch piston in the clutch drum Use caution as not to...

Page 278: ...ll the spring retainer ring Be sure ring is in full position in the groove Install one outer half disc with friction material away from the piston Install one steel disc Alternate friction and steel d...

Page 279: ...213 Install one outer half disc with friction material down Install the modulator spring with large diameter up to the backing plate Install the backing plate Install the backing plate snap ring www m...

Page 280: ...ocating rings Install the clutch gear in the clutch drum Align splines on clutch gear with internal teeth of steel discs Do not force this operation Gear splines must be in full po sition with interna...

Page 281: ...SECTION 21 TRANSMISSION 215 Tap the outer bearing into the clutch hub Install the outer bearing retaining ring Install the clutch shaft sealing rings www maskinisten net Copyright...

Page 282: ...MISSION SECOND CLUTCH DRUM DISASSEMBLY Press the upper output gear from the second shaft Press the gear from second shaft Remove the gear retaining ring Remove the clutch shaft sealing rings www maski...

Page 283: ...MISSION 217 Use bearing puller to remove the clutch hub and the front bearing Remove the clutch shaft front bearing Remove the bearing washer Remove the clutch hub and the outer bearing www maskiniste...

Page 284: ...TION 21 TRANSMISSION Use a bearing puller to remove the clutch hub inner bearing Remove the clutch hub inner bearing Remove the backing plate snap ring Remove the backing plate www maskinisten net Cop...

Page 285: ...SECTION 21 TRANSMISSION 219 Remove the modulation spring Remove the one outer half disc Remove the inner and the outer discs Remove the one outer half disc www maskinisten net Copyright...

Page 286: ...CTION 21 TRANSMISSION Compress the spring to remove the spring retaining ring Remove the spring retaining ring Remove the spring retainer Remove the clutch piston return spring www maskinisten net Cop...

Page 287: ...SECTION 21 TRANSMISSION 221 Remove the piston wear plate Remove the clutch piston assy www maskinisten net Copyright...

Page 288: ...rotating piston while holding a round object against the new sealing ring Rotate piston until sealing ring is flush with out er diameter of the piston Install the clutch piston inner seal Install the...

Page 289: ...e with the proper inner diameter to fit over shaft and against retainer ring A sharp blow with a soft hammer will compress the spring and seat retainer ring Be sure ring is in full position in the gro...

Page 290: ...steel discs until the proper amount of discs are installed First and last discs are steel Install one outer half disc with friction material down Install the modulator spring with large diameter up to...

Page 291: ...ear inner bearing into the place Install the clutch hub bearing locating rings Install the clutch gear in the clutch drum Align splines on clutch gear with internal teeth of steel discs Do not force t...

Page 292: ...ll the clutch hub outer bearing S WARNING Be sure that bearing shield is on the outside Tap the outer bearing into the place Install the bearing washer Warm the front bearing to 120 C install the bear...

Page 293: ...21 TRANSMISSION 227 Install the clutch shaft sealing rings Install the gear retaining ring Warm the gear to 150 C install the gear Warm upper output gear to 150 C install gear www maskinisten net Cop...

Page 294: ...TRANSMISSION OUTPUT SHAFT DISASSEMBLY Remove the oil baffle screws and the nuts Remove the oil baffle Remove the output shaft sealing rings Remove the output shaft gear retaining ring www maskinisten...

Page 295: ...SECTION 21 TRANSMISSION 229 Press the output gear from the shaft Remove the output gear Remove the oil baffle from the output shaft Remove the gear retaining ring www maskinisten net Copyright...

Page 296: ...230 SECTION 21 TRANSMISSION Remove the backing plate snap ring Remove the backing plate spacer Remove the backing plate Remove the one outer half disc www maskinisten net Copyright...

Page 297: ...21 TRANSMISSION 231 Remove the inner and the outer discs Remove the one outer half disc Compress the spring to remove the spring retaining ring Remove the spring retaining ring www maskinisten net Co...

Page 298: ...232 SECTION 21 TRANSMISSION Remove the spring retainer Remove the clutch piston spring Remove the piston wear plate Remove the piston assy www maskinisten net Copyright...

Page 299: ...g piston while holding a round object against the new sealing ring Rotate piston until sealing ring is flush with out er diameter of the piston Install the clutch piston inner seal Install the clutch...

Page 300: ...ring A sharp blow of a soft hammer will compress the spring and the seat retainer ring Be sure ring is in full position in the groove Install one outer half disc with friction material away from the...

Page 301: ...ECTION 21 TRANSMISSION 235 Install one half disc with friction material down Install the backing plate Install the backing plate spacer Install the backing plate snap ring www maskinisten net Copyrigh...

Page 302: ...ON 21 TRANSMISSION Install the oil baffle on the output shaft Install the output gear retaining ring Warm the gear to 150 C install the gear Install the output gear retaining ring www maskinisten net...

Page 303: ...l the output shaft sealing rings Install the rear oil baffle on the output shaft Install the oil baffle mounting screws the washer and the nuts and tighten the nuts to the specified torque Use Loctite...

Page 304: ...N DISCONNECT SHAFT DISASSEMBLY Use bearing puller to remove the disconnect shaft front bearing Remove the front bearing Remove the front bearing retaining ring Remove the clutch hub from the shaft www...

Page 305: ...SECTION 21 TRANSMISSION 239 Remove the clutch hub locating ring from the shaft www maskinisten net Copyright...

Page 306: ...TRANSMISSION DISCONNECT SHAFT ASSEMBLY Install the bushing if necessary Install the clutch hub locating ring Install the clutch hub on the shaft Install the front bearing retaining ring www maskiniste...

Page 307: ...SECTION 21 TRANSMISSION 241 Install the front bearing on the shaft Tap the bearing on the shaft www maskinisten net Copyright...

Page 308: ...SSION PUMP DRIVE SHAFT DISASSEMBLY Remove the rear bearing snap ring Use bearing puller to remove the rear bearing Remove the rear bearing from the shaft Remove the sealing ring from the shaft www mas...

Page 309: ...SMISSION 243 PUMP DRIVE SHAFT ASSEMBLY Install the sealing ring on the shaft Install the rear bearing on the shaft Tap the bearing into the place Install the rear bearing retainer ring www maskinisten...

Page 310: ...N INPUT SHAFT DISASSEMBLY Remove the input shaft rear sealing ring Remove the forward high gear retaining ring Remove the forward low gear retaining ring Remove the input shaft front sealing ring www...

Page 311: ...5 Use bearing puller to remove the input shaft front the bearing Remove the input shaft front bearing Remove the input shaft front bearing retaining ring Remove the forward low gear retaining ring www...

Page 312: ...246 SECTION 21 TRANSMISSION Press the forward low gear from the shaft www maskinisten net Copyright...

Page 313: ...PUT SHAFT ASSEMBLY Install the forward low gear retaining ring Warm the gear to 150 C install the gear Install the forward low gear retaining ring Install the input shaft front bearing retaining ring...

Page 314: ...nput shaft front sealing ring Warm the input shaft front bearing to 120 C install the bearing Turn the shaft and install the input shaft forward high gear retaining ring Install the input shaft rear s...

Page 315: ...HOUSING ASSEMBLY Install the safety valve ball spring and the plug Install the by pass valve ball spring and the plug Install the output shaft front oil seal Using suitable seal installer tap seal in...

Page 316: ...ing caution as not to damage any of the first shaft sealing rings Install the forward low shaft and the high shaft into the housing Use caution as not to damage the seal ing rings Install the disconne...

Page 317: ...sealing rings Install the baffle plate the mounting screws the washers and the nuts Tighten the nuts to the spec ified torque Use Loctite 243 Install the baffle plate the mounting screws the washers a...

Page 318: ...Install the suction tube into the housing Be sure ring is in the groove Install the suction tube retainer the mounting screw and the lock washer Use Loctite 243 Tighten the mounting screw to the spec...

Page 319: ...to 150 C install the gear Warm the upper output rear bearing to 120 C install the bearing Warm the reverse and 1st shaft rear bearing to 120 C install the bearing Warm the input shaft rear bearing to...

Page 320: ...bearing to 120 C install the bearing Warm the lower output shaft rear bearing to 120 C install the bearing Install the output shaft rear bearing retaining ring Install the gasket and the clutch press...

Page 321: ...pe snap ring pliers spread ears on output shaft rear bearing retaining ring Hold snap ring open Tap the transmission case into the place Tap the dowel pin in the transmission case and the converter ho...

Page 322: ...g ring Hold snap ring open pry or lift output shaft Be sure re taining ring is complete in the bearing groove Using a lifting eye or screw M12 Install the hole plug and the gasket Tighten the plug to...

Page 323: ...on the upper output seal Tap the seal into the place Install the upper output flange the O ring the wash er and the nut and tighten the nut to 339 407 Nm Install the pump drive shaft assy into the hou...

Page 324: ...pump drive shaft rear bearing retaining ring Install the pump hole cover the gasket the screws and the lock washers Tighten the pump hole cover screws Install the pump and the O ring into the converte...

Page 325: ...g screws and the lock washers then tighten the screws Install the converter assembly on the input shaft Install the drive plates on the converter Install the drive plate screws and the lock washers th...

Page 326: ...er the O ring the lock washers and the mounting screws Tighten the screws Install the oil filter and tighten to 30 38 Nm Install the output shaft front flange the O ring the washer and the nut Tighten...

Page 327: ...all the by pass valve spool into the solenoid housing and the spring into the transmission case Place the control valve on the transmission case Install the control valve mounting screws and the lock...

Page 328: ...N Install the gasket and the valve protection cover mounting screws then tighten the screws Install the air breather and tighten to 34 41 Nm Install the wiring connector nut and tighten to 6 8 Nm www...

Page 329: ...assembly from the side Z Install new pads assembly 17 in each torque plate 16 and 18 Z Install pad retention spring 21 into brake head assembly Be sure spring s feet are positioned properly in holes i...

Page 330: ...264 SECTION 21 TRANSMISSION 2 13 SPECIAL TOOLS P N CNH DESCRIPTION 380000676 Lifting tool www maskinisten net Copyright...

Page 331: ...em are in good condition and operating correctly The radiator must be clean to maintain the proper cooling and operating temperatures for the engine and transmission Air clean the radiator if neces sa...

Page 332: ...n the pump section Replace the pump Overheating Worn oil sealing rings Worn charging pump Low oil level Dirty oil cooler Restriction in cooler lines Remove disassemble and reassemble the converter Rep...

Page 333: ...may be blinking in some way as shown in the table below NOTE on an open circuit or on a battery connection at the ON OFF outputs a detection is made only when the corresponding output is in the OFF p...

Page 334: ...ition is indicated with a red LED Once the fault code has been deter mined proceed to fault codes FAULT SUBGROUP A GROUP INDICATION Input related LED 1 blinks red Output related LED 2 blinks red Other...

Page 335: ...started WHILE POWERING UP ignition on Leaving the self test mode is done by switching OFF the power of the Microprocessor ignition off Auto transmission only Auto Manual override POWERSHIFT LEVER POS...

Page 336: ...ever unit Key on power Select neutral and push kickdown button LED 1 red LED 4 orange Test with new powershift lever unit fitted YES T LED Blinks N LED Blinks Slower NO No input fault YES YES NO Other...

Page 337: ...to upshift keep the shift lever in this position during power up turn the ignition on and start the engine With engine running return Powershift lever to neu tral position and then place lever in forw...

Page 338: ...push kickdown button LED 1 red LED 5 orange F2 NO Check speed sensor has it failed YES T LED Blinks N LED Blinks Slower NO No input fault YES YES NO LED 1 red LED 5 red F3 NO Other input fault YES YES...

Page 339: ...Vdc Action of the Microprocessor Z no upshifts above second gear Z direction change while in Forward 3 or Forward 4 the actual reversal is preceded by a downshift se quence until second gear is obtain...

Page 340: ...wn button 1 red 7 green Check alternator output is it correct YES T LED Blinks N LED Blinks Slower NO No input fault YES YES NO Other input fault Check through F1 F2 F3 or F11 YES Check battery voltag...

Page 341: ...on in neutral If however at the time the fault was detected a fault was also present on the pressure modulator the mi croprocessor reverts to shutdown mode and re mains this way until power is removed...

Page 342: ...odulation solenoid NO Green No fault found YES Identify component by LED 1 Forward solenoid 2 Reverse solenoid 3 1 2 Solenoid 4 High low forward travel solenoid 5 4WD RWD solenoid 6 Direction modulati...

Page 343: ...ndicates its sta tus Output test Fault by LED Number The LED numbers correspond to the connector out put wires as follows Example LED 1 Forward solenoid colour Orange Output not connected or shorted t...

Page 344: ...1 orange YES Led 2 orange YES Check the forward cable of the powershift lever is it faulty YES Check the reverse cable of the powershift lever is it faulty YES Repair or replace NO NO YES Check revers...

Page 345: ...ault by LED Number The LED numbers correspond to the connector out put wires as follows Example LED colour Red and numbered 3 1 2 solenoid out put shorted to ground COLOUR STATUS GREEN Output OK ORANG...

Page 346: ...put test fault found NO Other LEDs are orange Proceed to F9 or F10 YES YES Led 3 orange or red YES YES Check 1 2 solenoid is it faulty YES Check the high low solenoid is it faulty YES Repair or replac...

Page 347: ...sals are possi ble but it has the advantage that the driver cannot be surprised by a sudden performance loss which could constitute a safety hazard in itself Direction Modulation Solenoid E03 Pin T Th...

Page 348: ...tion modulator open circuit Other non critical output fault F7 or F8 YES Repairor replace NO Check internal and external wiring of the direction modulation solenoid are they faulty NO NO YES Replace t...

Page 349: ...ically selected at power up if the integrity tests show that EPROM parameters are cor rupt but the microprocessor can still function as a transmission controller other component s integrity are intact...

Page 350: ...processor shifts to the input test mode As shown in the table below placing the shift lever in different positions in this mode illuminates its respec tive LED IMPORTANT selftest modes can only be sta...

Page 351: ...equest Direction Request Speed Temp sensor YES Perform input test and analyse faults if possible fault found NO YES Repair or replace Key on power YES Perform output test and check range modulation LE...

Page 352: ...nnector Disconnect the damaged loom and connect the limp home lead in its place Connect the plug end into the 12 V auxiliary socket or any available 12 V supply When seated in the cab start the engine...

Page 353: ...1 3 FAULT FINDING 24 2 FRONT AXLE 4WD CARRARO 26 2 1 SPECIFICATIONS 26 2 2 DISASSEMBLY AND ASSEMBLY 31 2 3 FAULT FINDING 77 3 FRONT AXLE 4WS CARRARO 80 3 1 SPECIFICATIONS 80 3 2 DISASSEMBLY AND ASSEM...

Page 354: ...2 SECTION 25 FRONT AXLES www maskinisten net Copyright...

Page 355: ...SECTION 25 FRONT AXLES 3 1 FRONT AXLE 2WD CARRARO 1 1 SPECIFICATIONS TYPE Front steering axle model 26 00 F27349 www maskinisten net Copyright...

Page 356: ...25 FRONT AXLES GREASING AND LUBRICATION DESCRIPTION POSITION Oil level plug 1 Air breather 2 Level fill and drain plug for reduction gear oil 3 Oil drain plug 4 Greasing points 5 www maskinisten net...

Page 357: ...e oil breather 2 to release possible internal pressure Unscrew the level plug 1 and fill to the bottom of the level plug hole with the specified oil Wait to allow the oil to flow through the axle Chec...

Page 358: ...AXLES 1 2 DISASSEMBLY AND ASSEMBLY FRONT AND REAR SUPPORT Disassembly Remove the rear support 10 from the differential support F27351 7 1 9 1 4 5 6 15 13 11 1 10 2 14 12 8 9 8 3 F27352 10 www maskini...

Page 359: ...the bush 12 from the rear support 10 Remove the bushes 1 from the rear support 10 Remove the bush 13 and the thrust washer 14 from differential support only if necessary NOTE it is advisable to heat...

Page 360: ...t washer 5 from axle housing 6 only if necessary NOTE it is advisable to heat the bush 4 to make easy this operation this is a destructive operation for the bush Insert the thrust washer 14 into the d...

Page 361: ...th the bolt 8 hole Mount the bolt 8 Lubricate with grease a new O ring 11 Insert the O ring 11 in the rear support 10 Insert the rear support 10 on the differential sup port S WARNING Do not damage th...

Page 362: ...1 contact surface Assemble the bushes 1 to the front support 2 with a pad and a hammer Assemble the bush 3 into the front support 2 with a suitable driver and a hammer S WARNING Align the bush hole w...

Page 363: ...the nut 1 with an appropriate hammer in order to separate the tie rod 3 from the swivel housing 2 S WARNING Don t beat on the threaded pin end of the tie rod 3 NOTE this is a destructive operation fo...

Page 364: ...r body 19 and remove it from the rod 17 Remove the rod 17 from the cylinder body 19 Remove all the seals and O rings 13 14 16 18 20 and 21 from the cylinder body 19 the cylinder head 15 and the rod 17...

Page 365: ...e tie rod 12 so that its ball joint can be in serted into the swivel housing 8 NOTE it is important to unscrew the locknut 11 to carry out this operation Repeat the whole sequence of the mentioned ope...

Page 366: ...14 SECTION 25 FRONT AXLES Screw the locknuts 4 and 11 of the tie rods 3 and 12 only when the toe in adjustment has been carried out F27238 12 11 www maskinisten net Copyright...

Page 367: ...HEEL HUB Disassembly Unscrew and remove the fastening screws 1 of the cover 2 Remove the cover 2 and the O ring 6 F27365 1 2 3 4 5 6 7 8 9 10 14 15 16 17 20 18 19 18 11 21 12 13 12 22 1 2 6 F27366 www...

Page 368: ...bearing cups 5 and 8 using a ham mer and a suitable drift Remove the bearing cone 8 from the swivel hous ing end using a suitable extractor Unscrew and remove the fastening bolts 12 from the upper 11...

Page 369: ...nd 18 If it has been previously removed reassemble the steering stop composed by the screw 15 and nut 14 NOTE do not tighten the nut 14 until the steering angle adjustment has been done Insert the thr...

Page 370: ...o the seal ring Assemble the swivel housing 10 on the axle shaft Assemble the king pins the lower 13 and the up per 11 and tighten the retaining screws 12 to the requested torque Assemble both bearing...

Page 371: ...he wheel hub 7 on the swivel housing 10 and insert the bearing cone 5 Assemble the thrust washer 4 Screw the screws 3 Assemble a new O ring 6 Assemble the cover 2 and screw two screws 1 Tighten the sc...

Page 372: ...and lock them with two nuts on the wheel hub stud bolt S WARNING The two bars should be fixed on their middle so that they are perpendicular to the supporting surface and parallel to the pinion shaft...

Page 373: ...e in value A is referred to the exter nal diameter of the wheel hubs flange therefore the measured value M at the bars ends must be relat ed to the ratio between length of the bar and flange diameter...

Page 374: ...f the central body pinion side so that the two bars form an acute angle at the maximum steering Adjust a protractor to the requested angle and posi tion it on the long bar Move a wheel side till it fo...

Page 375: ...SECTION 25 FRONT AXLES 23 Steer completely towards the other side and repeat the same operation F27348 www maskinisten net Copyright...

Page 376: ...ehicle with a broken half shaft It is acceptable to move the vehicle engine off unloaded a few metres away only 5 Bent half shaft Replace the half shaft 6 Incorrect wheel adjustment Verify group integ...

Page 377: ...ded intervals Oil leakage form gaskets and seals Prolonged functioning at high temperature of the oil Oil gasket assembled incorrectly Seal lip damaged Contaminated oil Replace the gasket and the matc...

Page 378: ...26 SECTION 25 FRONT AXLES 2 FRONT AXLE 4WD CARRARO 2 1 SPECIFICATIONS TYPE Front steering axle model 26 16 POWERSHIFT POWERSHUTTLE RATIO 12 8 12 333 13 714 14 308 F27203 www maskinisten net Copyright...

Page 379: ...on use recommended oil enriched in additives Note do not use synthetic or vegetable oil without consent of the axle manufacturer Amber Mastertran NH 410 C DESCRIPTION POSITION Oil level plug 1 Air bre...

Page 380: ...internal pressure Unscrew the level plug 1 and fill to the bottom of the level plug hole with the specified oil Wait to allow the oil to flow through the axle Check oil level and fill to the specifie...

Page 381: ...AXLES 29 Rotate the wheel end so that the hole 3 is in the po sition shown in figure Fill to the bottom of the fill plug hole with specified oil Tighten the plug 3 to the requested torque www maskinis...

Page 382: ...NT AXLES MOUNTING SCREW TORQUE F27211 80 Nm 165 Nm 25 Nm 120 Nm 8 Nm 8 Nm 8 Nm 10 Nm 300 Nm 120 Nm 169 Nm 57 Nm 84 Nm 84 Nm 60 Nm 120 Nm 266 Nm 13 Nm 95 Nm 150 Nm 8 Nm 120 Nm 95 Nm 165 Nm www maskinis...

Page 383: ...AND ASSEMBLY FRONT AND REAR SUPPORT Disassembly Remove the nut 3 and the bolt 2 and extract the flange 1 from the pinion shaft end 14 F27212 20 21 18 17 16 15 12 9 14 8 5 6 3 19 13 11 10 7 4 2 1 2 1...

Page 384: ...support Remove the O ring 6 from the bush 8 in rear sup port 5 NOTE this is a destructive operation for the O ring Remove the bolt 4 Remove the bush 8 from the rear support 5 Remove the bushes 6 from...

Page 385: ...the seal rings Remove the bush 9 and the thrust washer 10 from differential support only if necessary NOTE it is advisable to heat the bush 9 to make easy this operation this is a destructive operati...

Page 386: ...is a destructive operation for the bush Insert the thrust washer 10 into the differential sup port Heat the bush 9 at 110 120 C then assemble it to the differential support If necessary assemble the b...

Page 387: ...ble the bushes 6 to the rear support 5 with a pad and a hammer Assemble the bush 8 in the rear support 5 S WARNING Align the bush hole with the bolt 4 hole Mount the bolt 4 Lubricate with grease a new...

Page 388: ...ge 1 with the bolt 2 and the nut 3 Tighten the nut 3 to the requested torque Insert the thrust washer 16 into the front support seat Heat the bush 17 at 110 120 C then assemble it to the axle housing...

Page 389: ...port 20 with a suitable driver and a hammer S WARNING Align the bush hole with the bolt 19 hole Mount the bolt 19 Insert the front support 20 on the axle housing Tighten the bolt 19 to the requested t...

Page 390: ...on the nut 1 with an appropriate hammer in order to disjoin the tie rod 3 from the swivel hous ing 2 S WARNING Don t beat on the threaded pin end of the tie rod 3 NOTE this is a destructive operation...

Page 391: ...er body 19 and remove it from the rod 17 Remove the rod 17 from the cylinder body 19 Remove all the seals and O rings 13 14 16 18 20 and 21 from the cylinder body 19 the cylinder head 15 and the rod 1...

Page 392: ...he tie rod 12 so that its ball joint can be in serted into the swivel housing 8 NOTE it is important to unscrew the locknut 11 to carry out this operation Repeat the whole sequence of the mentioned op...

Page 393: ...SECTION 25 FRONT AXLES 41 Screw the locknuts 4 and 11 of the tie rods 3 and 12 only when the toe in adjustment has been carried out F27238 12 11 www maskinisten net Copyright...

Page 394: ...42 SECTION 25 FRONT AXLES REDUCTION GEAR Disassembly Drain the oil completely from the planetary carrier F27239 3 1 2 4 5 6 7 8 9 10 F27240 www maskinisten net Copyright...

Page 395: ...pin 4 Z remove the triangular plate 9 Z extract the gears 8 from the pins Z collect the bearings 7 and check their conditions Z collect the thrust washer 6 NOTE with the new gears it is advisable to a...

Page 396: ...le the triangular plate 9 and the related snap rings 10 Insert a new O ring 5 on the planetary carrier cover 1 Assemble the planetary carrier cover 1 onto the wheel hub Assemble the screws 3 and tight...

Page 397: ...haft and fit into the cardan shaft With the lever push the cardan shaft in the direction of the wheel hub to allow the removal of the snap ring S WARNING Do not damage the cardan shaft F27248 1 3 4 7...

Page 398: ...ts hous ing screw in two of the just removed screws 5 in the threaded extraction holes Extract and remove the ring gear carrier 7 together with the ring gear 4 Remove the retaining ring 8 and separate...

Page 399: ...ng 12 from the swivel housing end using a suitable extractor Unscrew and remove the fastening bolts 19 and 17 from the upper 18 and lower 16 king pin S WARNING Before removing the king pins 16 and 18...

Page 400: ...hammer If it has been previously removed reassemble the steering stop composed by the screw 21 and nut 20 NOTE do not tighten the nut 20 until the steering angle adjustment has been done Insert the b...

Page 401: ...washers 25 and 28 on the king pin 16 and 18 housings Secure the swivel housing 14 with a belt or a rope to a hoist or to any other supporting device Protect the splined end of the axle shaft by windin...

Page 402: ...l housing 14 end Assemble the wheel hub 11 on the swivel housing 14 and fit the bearing 9 Position the ring gear carrier 7 on a workbench and force the bushes 6 to the carrier 7 surface level with the...

Page 403: ...ening the ring gear car rier 7 and tighten to the specified torque The special operation Set Right of the bearings 9 and 12 does not require preload or backlash ad justment Anyway before assembling ne...

Page 404: ...2 and 3 on the end of the cardan shaft Insert the snap ring 1 on the end of the shaft and push it into its seat NOTE check that the snap ring 1 is correctly fitted in its seat Push in the cardan shaft...

Page 405: ...SECTION 25 FRONT AXLES 53 CARDAN SHAFTS Disassembly Remove the cardan shaft 6 from the axle shaft 1 F27272 1 2 3 4 5 6 6 1 F27273 www maskinisten net Copyright...

Page 406: ...pper king pin bush 2 and the bearing cup 3 at a temperature lower than 100 C with liquid ni trogen S WARNING Wear safety gloves Assemble the bush 2 on the upper king pin seat with the special tool 380...

Page 407: ...5 Assemble the seal ring 5 S WARNING Positioning the seal ring 5 as in figure Insert the cardan shaft 6 into the axle shaft 1 S WARNING Be careful not to damage the seal ring F27278 5 6 1 F27273 www m...

Page 408: ...rential Loosen and remove the screws 2 of the differential support 1 Remove the differential support 1 from the axle housing 14 S WARNING Support the differential support with a rope or other appropri...

Page 409: ...e marks to avoid inverting them during re as sembly Mark the area between the ring nuts 3 and 7 and the differential support 1 as well Unscrew the adjuster ring nuts 3 and 7 using tool 380000406 and a...

Page 410: ...gs are not replaced Assemble the differential assy complete with bear ings on the differential carrier S WARNING Check the correct assembly side of the ring gear Move the differential assy so that the...

Page 411: ...terna tively and note the pinion ring gear backlash meas ured with the comparator Repeat the operation on 2 or more points teeth ro tating the crown gear so that to obtain an average value Check if th...

Page 412: ...range T P 3 90 P 5 90 daN where P is the effectively measured pinion preload ing See section Pinion assembly S WARNING All preloadings must be measured without the seal ring If the measurement is not...

Page 413: ...faces make sure that they are perfectly clean degrease and clean them with ap propriate detergents Spread a film of adhesive on the contact surface be tween the axle beam 14 and the differential carri...

Page 414: ...r 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 or der to adjust the backlash X Excessive contact at the too...

Page 415: ...SECTION 25 FRONT AXLES 63 DIFFERENTIAL GROUP Disassembly Use an extractor to remove bearing 12 F27306 12 www maskinisten net Copyright...

Page 416: ...11 S WARNING This operation makes both differential half boxes free so take care not to lower the inner compo nents Remove the ring gear 11 by means of a hammer Check the marking points 3 and 10 that...

Page 417: ...half housing 3 on a workbench and as semble all inner components the discs 4 the gears 5 the shaft 9 the gears 7 the spherical washers 6 and the pin 8 Assemble the two half housings of the differentia...

Page 418: ...Apply Loctite 242 on the thread of screws 1 Tighten the screws 1 to the specified torque Press the bearing 12 or assemble after preheat ing Press the bearing 2 F27316 1 F27315 1 12 F27317 2 F27318 www...

Page 419: ...INION GROUP Disassembly Position the differential carrier in a vise Unscrew the ring nut 10 using the special tool 380002218 NOTE this operation will irretrievably damage the ring nut 10 10 F27320 www...

Page 420: ...inion 1 Collect the washers 4 and 6 the spacer 5 and the bearing 8 Place the differential carrier 7 on a flat surface and remove the bearing cups 3 and 8 using a drift and a hammer To remove the beari...

Page 421: ...the bearing cups 3 and 8 Prepare the kit consisting of the special tools called false pinion 380002219 and false differential box 380000407 380000440 and a depth gauge Insert the bearing 3 and 8 in th...

Page 422: ...ge to measure distance X dis tance between the axis of the differential bearings and the point at which the pinion head is supported or base of the bearing In order to determine the necessary thicknes...

Page 423: ...ecial tool 380002224 under a press making sure that it is well set Insert the shims 4 and 6 and a new spacer 5 NOTE use always a new spacer 5 Insert the pinion assy 1 into the differential support hou...

Page 424: ...dvisable to beat slightly both pinion ends with a soft hammer so as to help setting the bearings Carry out the preloading measurement P of the pin ion taper roller bearings using a dynamometer whose c...

Page 425: ...and lock them with two nuts on the wheel hub stud bolt S WARNING The two bars should be fixed on their middle so that they are perpendicular to the supporting surface and parallel to the pinion shaft...

Page 426: ...e in value A is referred to the exter nal diameter of the wheel hubs flange therefore the measured value M at the bars ends must be relat ed to the ratio between length of the bar and flange diameter...

Page 427: ...of the central body pinion side so that the two bars form an acute angle at the maximum steering Adjust a protractor to the requested angle and posi tion it on the long bar Move a wheel side till it f...

Page 428: ...76 SECTION 25 FRONT AXLES Steer completely towards the other side and repeat the same operation F27348 www maskinisten net Copyright...

Page 429: ...ponents Vehicles with wide steering angle may proceed with kicks have steering difficulty or cause pneumatic wearing at sharp turns Reduce the steering angle to minimum and decelerate when the vehicle...

Page 430: ...e right levels and replace according to the recommended program Overheated ring and pinion teeth See if gear teeth have faded Prolonged functioning at high temperatures Incorrect lubrication Low oil l...

Page 431: ...roup Replace half shaft if required Thrust washer surface worn out or scratched Insufficient lubrication Incorrect lubrication Contaminated oil Use correct lubrication and fill up to right level Repla...

Page 432: ...80 SECTION 25 FRONT AXLES 3 FRONT AXLE 4WS CARRARO 3 1 SPECIFICATIONS TYPE Front steering axle model 26 28 POWERSHIFT SELF LOCKING RATIO 18 46 F27378 www maskinisten net Copyright...

Page 433: ...d in additives Note do not use synthetic or vegetable oil without consent of the axle manufacturer Akcela Nexplore MAT3525 DESCRIPTION POSITION Oil level plug 1 Air breather 2 Level fill and drain plu...

Page 434: ...rnal pressure Unscrew the level plug 1 and fill to the bottom of the level plug hole with the specified oil Wait to allow the oil to flow through the axle Check oil level and fill to the specified lev...

Page 435: ...AXLES 83 Rotate the wheel end so that the hole 3 is in the po sition shown in figure Fill to the bottom of the fill plug hole with specified oil Tighten the plug 3 to the requested torque www maskinis...

Page 436: ...2 DISASSEMBLY AND ASSEMBLY FRONT AND REAR SUPPORT Disassembly Remove the nut 3 and the bolt 2 and extract the flange 1 F27380 21 15 7 1 3 8 6 5 11 18 22 17 16 14 10 12 13 2 4 9 19 23 F27381 1 3 2 www...

Page 437: ...nd remove the flange 12 Loosen the bolt 4 Take the rear support 5 out from the differential support Remove the O ring 7 from the rear support 5 NOTE this is a destructive operation for the O ring 7 F2...

Page 438: ...the rear support 5 Remove the bushes 6 from the rear support 5 Remove the washer 10 from the differential sup port only if necessary Loosen the bolt 19 Take the front support 20 out from the axle hous...

Page 439: ...r 16 from the axle housing 15 only if necessary NOTE it is advisable to heat the bush 17 to make easy this operation this is a destructive operation for the bush Insert the washer 10 into the differen...

Page 440: ...he differential support S WARNING Do not damage the O ring when inserting the rear support on the central body Tighten the bolt 4 to the specified torque Assemble the lube nibble 9 Insert the washer 1...

Page 441: ...h a suitable driver and a hammer S WARNING Align the bush hole with the bolt 19 hole Mount the bolt 19 Assemble O ring 22 Insert the front support 20 on the axle housing Tighten the bolt 19 to the spe...

Page 442: ...S Assemble the seal ring 13 use the special tool 380002225 Assemble the flange 1 Lock the flange 1 with the bolt 2 and the nut 3 Tighten the nut 3 to the specified torque F27382 13 F27381 1 3 2 www ma...

Page 443: ...nut 1 with an appropriate hammer in order to separate the tie rod 3 from the swivel housing 2 S WARNING Don t beat on the threaded pin end of the tie rod 3 NOTE this is a destructive operation for th...

Page 444: ...the rod 20 Remove the rod 20 from the cylinder body 22 Remove all the seals and O rings 16 17 19 21 23 and 24 from the cylinder body 22 the cylinder head 18 and the rod 20 Assemble new seals and O ri...

Page 445: ...e swivel housing 11 with the axle Screw in the tie rod 10 so that its ball joint can be inserted into the swivel housing arm 11 NOTE it is important to unscrew the locknut 9 to carry out this operatio...

Page 446: ...94 SECTION 25 FRONT AXLES Screw the locknuts 4 and 9 of the tie rods 3 and 10 only when the toe in adjustment has been car ried out F29526 10 9 4 3 www maskinisten net Copyright...

Page 447: ...SECTION 25 FRONT AXLES 95 REDUCTION GEAR Disassembly Drain the oil completely from the planetary carrier F27404 8 7 6 11 9 10 5 1 4 3 2 F27240 www maskinisten net Copyright...

Page 448: ...t the bearings 7 and check their conditions Z collect the washer 6 NOTE with the new gears it is advisable to assem ble new needles Position the planetary carrier cover 1 on a work bench Insert the wa...

Page 449: ...1 onto the wheel hub Assemble the screws 3 and tighten to the specified torque To up the oil on the wheel hub Assemble the plug 2 onto the planetary carrier cover 1 and tighten to the specified torqu...

Page 450: ...shaft and fit into the cardan shaft With the lever push the cardan shaft in the direction of the wheel hub to allow the removal of the snap ring S WARNING Do not damage the cardan shaft F27409 1 3 4...

Page 451: ...its hous ing screw in two of the just removed screws 5 in the threaded extraction holes Extract and remove the ring gear carrier 7 together with the ring gear 4 Remove the retaining ring 8 and separa...

Page 452: ...cone 12 from the swivel hous ing end using a suitable extractor Unscrew and remove the fastening bolts 19 and 17 from the upper 18 and lower 16 king pin S WARNING Before removing the king pins 16 and...

Page 453: ...mmer If it has been previously removed reassemble the steering stop composed by the screw 21 and nut 20 NOTE do not tighten the nut 20 until the steering angle adjustment has been done Insert the bush...

Page 454: ...lined end of the axle shaft by winding it with an adhesive tape to avoid damage to the seal ring Assemble the king pins the lower 16 and the up per 18 and tighten the retaining screws 17 and 19 to the...

Page 455: ...02667 At least two bushes diametrically opposed should be set slightly higher than the carrier surface level to be used as dowel pins Preassemble the ring gear carrier 7 and the ring gear 4 with the r...

Page 456: ...the swivel housing 14 and the axle shaft and fit into the cardan shaft With the lever push the cardan shaft in the direction of the wheel hub to allow an easier fitting of the snap ring Assemble the t...

Page 457: ...SECTION 25 FRONT AXLES 105 CARDAN SHAFTS Disassembly Remove the cardan shaft 4 from the axle shaft 1 F27417 1 4 3 2 4 1 F27418 www maskinisten net Copyright...

Page 458: ...to damage the bush seat Assemble the bush 2 on the axle beam 1 with the special tool 380002226 and a hammer Assemble the seal ring 3 on the axle beam with the special tool 380002670 and a hammer NOTE...

Page 459: ...ifferential Loosen and remove the screws 2 of the differential support 1 Remove the differential support 1 from the axle housing 14 S WARNING Support the differential support with a rope or other appr...

Page 460: ...ce marks to avoid inverting them during re as sembly Mark the area between the ring nuts 3 and 7 and the differential support 1 as well Unscrew the adjuster ring nuts 3 and 7 using tool 380000406 and...

Page 461: ...gs are not replaced Assemble the differential assy complete with bear ings on the differential carrier S WARNING Check the correct assembly side of the ring gear Move the differential assy so that the...

Page 462: ...rna tively and note the pinion ring gear backlash meas ured with the comparator Repeat the operation on 2 or more points teeth ro tating the crown gear so that to obtain an average value Check if the...

Page 463: ...range T P 3 90 P 5 90 daN where P is the effectively measured pinion preload ing See section Pinion assembly S WARNING All preloadings must be measured without the seal ring If the measurement is not...

Page 464: ...rfaces make sure that they are perfectly clean degrease and clean them with ap propriate detergents Spread a film of adhesive on the contact surface be tween the axle beam 14 and the differential carr...

Page 465: ...ar 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 or der to adjust the backlash X Excessive contact at the to...

Page 466: ...114 SECTION 25 FRONT AXLES DIFFERENTIAL GROUP STANDARD Disassembly Use an extractor to remove bearing 10 F27437 4 3 2 8 1 6 8 7 6 5 10 9 11 13 12 7 F27438 10 www maskinisten net Copyright...

Page 467: ...r 11 S WARNING This operation makes both differential half boxes free so take care not to lower the inner compo nents Remove the ring gear 11 by means of a hammer Check the marking points 3 and 9 that...

Page 468: ...t 8 the gears 7 and the spheri cal washers 6 Remove the gear 12 and the shim 13 Apply a thin layer of Molicote G n plus paste on the half housings of differential 3 and 9 S WARNING Remove rests of dop...

Page 469: ...us on the gears 5 and 12 and on the gears 7 Assemble the gear 12 and the shim 13 Position the shaft 8 the gears 7 and the spherical washers 6 Assemble the gear 5 and the shim 4 5 7 7 12 F27444 12 13 F...

Page 470: ...S WARNING Carefully check that the marks of both differential half housings coincide Assemble the ring gear 11 by means of a hammer Apply Loctite 242 on the thread of screws 1 Tighten the screws 1 to...

Page 471: ...SECTION 25 FRONT AXLES 119 Press the bearing 10 or assemble after preheat ing Press the bearing 2 10 F29010 2 F27318 www maskinisten net Copyright...

Page 472: ...20 SECTION 25 FRONT AXLES DIFFERENTIAL GROUP SELF LOCKING Disassembly Use an extractor to remove bearing 13 F27448 4 3 2 8 9 7 6 5 1 10 8 9 12 5 13 14 4 6 11 10 F27449 13 www maskinisten net Copyright...

Page 473: ...14 S WARNING This operation makes both differential half boxes free so take care not to lower the inner compo nents Remove the ring gear 14 by means of a hammer Check the marking points 3 and 12 that...

Page 474: ...T AXLES Assemble the discs 4 and 5 Remove the sun gear 11 Remove the shaft 10 the gears 8 and the spher ical washers 9 Remove the sun gear 7 4 5 F27452 11 F27453 9 8 9 8 10 F27454 7 F27455 www maskini...

Page 475: ...Molicote G n plus paste on the half housings of differential 3 and 12 S WARNING Remove rests of dope Apply a thin layer of Molicote G n plus on the gears 7 and 11 and on the gears 8 Assemble discs 4 a...

Page 476: ...RONT AXLES Assemble the gear 7 Position the shaft 10 the gears 8 and the spher ical washers 9 Assemble the gear 11 Assemble discs 4 and 5 7 F27455 9 8 9 8 10 F27454 11 F37839 4 5 F27452 www maskiniste...

Page 477: ...S WARNING Carefully check that the marks of both differential half housings coincide Assemble the ring gear 14 by means of a hammer Apply Loctite 242 on the thread of screws 1 Tighten the screws 1 to...

Page 478: ...126 SECTION 25 FRONT AXLES Press the bearing 13 or assemble after preheat ing Press the bearing 2 13 F27460 2 F27318 www maskinisten net Copyright...

Page 479: ...isassembly Position the differential carrier in a vise Unscrew the ring nut 10 using the special tool 380002218 NOTE this operation will irretrievably damage the ring nut 10 F27461 8 9 10 3 4 5 6 7 1...

Page 480: ...inion 1 Collect the washers 4 and 6 the spacer 5 and the bearing 8 Place the differential carrier 7 on a flat surface and remove the bearing cups 3 and 8 using a drift and a hammer To remove the beari...

Page 481: ...the bearing cups 3 and 8 Prepare the kit consisting of the special tools called false pinion 380002219 and false differential box 380000407 380000440 and a depth gauge Insert the bearing 3 and 8 in t...

Page 482: ...ure distance X dis tance between the axis of the differential bearings and the point at which the pinion head is supported or base of the bearing In order to determine the necessary thickness value S...

Page 483: ...4 under a press making sure that it is well set Insert the shims 4 and 6 and a new spacer 5 NOTE use always a new spacer 5 Insert the pinion assy 1 into the differential support housing 7 and the bear...

Page 484: ...advisable to beat slightly both pinion ends with a soft hammer so as to help setting the bearings Carry out the preloading measurement P of the pin ion taper roller bearings using a dynamometer whose...

Page 485: ...des and lock them with two nuts on the wheel hub stud bolt S WARNING The two bars should be fixed on their middle so that they are perpendicular to the supporting surface and parallel to the pinion sh...

Page 486: ...oe in value A is referred to the exter nal diameter of the wheel hubs flange therefore the measured value M at the bars ends must be relat ed to the ratio between length of the bar and flange diameter...

Page 487: ...of the central body pinion side so that the two bars form an acute angle at the maximum steering Adjust a protractor to the requested angle and posi tion it on the long bar Move a wheel side till it...

Page 488: ...136 SECTION 25 FRONT AXLES Steer completely towards the other side and repeat the same operation F27348 www maskinisten net Copyright...

Page 489: ...ponents Vehicles with wide steering angle may proceed with kicks have steering difficulty or cause pneu matic wearing at sharp turns Reduce the steering angle to minimum and decelerate when the vehicl...

Page 490: ...gear teeth have faded Prolonged functioning at high temperatures Incorrect lubrication Low oil level Contaminated oil Replace bevel gear set Use proper lubrication fill up to right level and replace...

Page 491: ...Incorrect lubrication Contaminated oil Use correct lubrication and fill up to right level Replace at intervals recommended Replace all scratched washers and those with a thickness by 0 1 mm lower than...

Page 492: ...alf beam 380002227 Assembly of seal ring in the wheel hub 380002432 Assembly of sliding block in the swivel housing 380002660 Assembly of bushing in the swivel housing 380002661 Assembly of seal ring...

Page 493: ...ND OPERATION 3 1 2 SPECIFICATIONS 6 1 3 DISASSEMBLY AND ASSEMBLY 8 1 4 FAULT FINDING 27 2 REAR AXLE 4WS CARRARO 28 2 1 SPECIFICATIONS 28 2 2 DISASSEMBLY AND ASSEMBLY 32 2 3 FAULT FINDING 81 3 SPECIAL...

Page 494: ...2 SECTION 27 REAR AXLE www maskinisten net Copyright...

Page 495: ...oupling has dog teeth which engage with the dog teeth on the differential housing lock adaptor If the dog teeth are not aligned the spring engage ment link will be preloaded ensuring rapid and full to...

Page 496: ...ect drive to both rear wheels The lock will remain engaged until either of the foot brakes are applied and the machine stops or by dis engaging the switch The warning lamp on the in strument panel wil...

Page 497: ...ck pedal 1 with your heel until the lock is felt to engage The lock will automatically disengage when traction at the rear wheels equalizes If a rear wheel spins at speed reduce the engine speed to id...

Page 498: ...LE 1 2 SPECIFICATIONS LUBRICATION Oil capacity 21 2 litres Oil specification Akcela Hy Tran Ultra MAT3525 AoA Axle oil additive 0 8 litres POWERSHIFT POWERSHUTTLE RATIO 4 62 1 4 11 1 F29550 www maskin...

Page 499: ...1 Nm 3 Screw of front flange 136 170 Nm 4 Screw to fixed rear axle to the chassis 800 Nm 5 Screw 11 14 Nm 6 Screw of block 57 76 Nm 7 Screw of baffle oil 43 51 Nm 8 Plug 27 34 Nm 9 Screw 32 41 Nm 10 S...

Page 500: ...uitable clean container Remove the pipes from both sides of the axle half shafts Plug the brake pipes to prevent any dirt or contamination entering the brake system Remove the 4 attaching screws from...

Page 501: ...the remaining screws 1 Remove the left housing of the half beam 2 with the differential 3 using the tool 380000990 from the axle central body 4 At this point it is possible to remove from the left ho...

Page 502: ...Screw 9 Bearing 10 Thrust washer 11 Side gear 12 Spider assembly 13 Side gear 14 Thrust washer 15 Differential half housing 16 Bearing screw Prior to separating the differential mark the two half hous...

Page 503: ...ing 4 inner dog 5 from the housing 6 Carefully inspect all moving parts for signs of scor ing wear or damage if evident replace with new parts By means of an extractor remove the bearing 16 Loosen and...

Page 504: ...EMOVAL 1 Ring nut 2 Lock pin 3 Washer 4 Seal 5 Coupling 6 Bearing 7 Spacer 8 Flange 9 Disc 10 Seal 11 Bearing 12 Pinion 13 Bearing 14 Safety ring 15 Screw Remove the lock pin 2 to unlock the ring nut...

Page 505: ...675 hold the coupling 5 steady while loosening the ring nut 1 Remove the ring nut 1 the washer 3 and the gas ket 4 Remove the coupling 5 Loosen and remove the screws 15 Remove flange 8 Remove the bear...

Page 506: ...the snap ring 14 from the axle inner cen tral body Using an rubber hammer take out the pinion 12 Remove from the pinion 12 the spacer 7 and by means of extractors the bearings 11 and 13 12 14 F29553...

Page 507: ...sing brake inner 8 Baffle oil powershuttle 9 Screw 10 Shim 11 Block powershuttle 12 Washer 13 Screw 14 Screw 15 Housing brake inner 16 Housing brake outer 17 Screw 18 Baffle oil powershift 19 Block po...

Page 508: ...le the block 11 with the shims 10 Loosen and remove the screws 9 Remove the housing brake inner 7 Remove the brake pads 6 and the intermediate disks 5 Remove the brake piston 4 and the outer housing b...

Page 509: ...ifold brake tube 9 Screw 10 Screw bleeder 11 O ring 12 Axle housing assy right or left 13 Bearing 14 Seal 15 Shaft with wheel hub 16 Ring gear The brake manifold 8 can be removed by loosen ing and rem...

Page 510: ...support 16 remove the retainer 2 the retaining screws 3 the washer 4 and the shim 5 Remove the gear carrier assy 6 If necessary it is possible to disassemble the gear carrier assy Z Remove the retaini...

Page 511: ...amage and repair or replace Position the axle housing 12 to allow removal of the shaft with wheel hub 15 Using the puller tool 380000986 and the slide ham mer 380000987 remove the bearing cups 13 from...

Page 512: ...uction heater heat the bearing sufficiently to expand it enough to allow it to easily seat onto the half shaft After bearing removal disassemble the seal 14 from the shaft with wheel hub 15 NOTE alway...

Page 513: ...he flange 1 and torque to 406 Nm with spanner to the locknut 2 Use a torque metre 1 to check rolling resistance when the assembly is fitted back into the axle The rolling resistance should be 1 3 Nm L...

Page 514: ...Resultant value refer to the ta ble for the correct shim to replace the 2 286 one IMPORTANT increasing shim thickness will reduce preload Decreasing shim thickness will increase preload Z fit selected...

Page 515: ...he dimensions shown Fit bridging bar 1 across the rear axle housing flange and use a torque metre 2 to check rolling re sistance which should be 2 3 10 Nm NOTE the brake housing brake pads and sun gea...

Page 516: ...rear axle housing flange with spacers 2 located be tween the axle housing flange and the tool Measure the gap between the bridge tool and the gauge ring using a feeler gauge 3 Refer to the table to d...

Page 517: ...the centre housing with the differential assy in stalled and centered we check the distance from the back of the bevel gear to the trumpet mounting face of the centre housing During this measure ment...

Page 518: ...ive you the minimum gap between the thrust block and the back of the differential bevel gear Based on this calculation and the attached shimming chart people find the shims to be used Shim pack thickn...

Page 519: ...haft rod fork or pivot shaft damaged broken Damaged or broken teeth on differential lock adaptor or coupling Solenoid valve sticking not operating Solenoid valve electrical connection poor or coil not...

Page 520: ...28 SECTION 27 REAR AXLE 2 REAR AXLE 4WS CARRARO 2 1 SPECIFICATIONS Rear steering axle model 26 32M POWERSHIFT SELF LOCKING RATIO 19 038 www maskinisten net Copyright...

Page 521: ...ched in additives Note do not use synthetic or vegetable oil without consent of the axle manufacturer Akcela Nexplore MAT3525 DESCRIPTION POSITION Level and fill plug for differential oil 1 Air breath...

Page 522: ...en tighten them to the specified torque Before draining the oil position the wheel hub so that the filler cap is in the highest point then loosen the plug 3 to release possible internal pressure Posit...

Page 523: ...fore draining the oil loosen the breather 6 to re lease possible internal pressure Check oil level and top up if necessary Tighten the plug with a torque wrench to the pre scribed torque F28009 6 www...

Page 524: ...32 SECTION 27 REAR AXLE 2 2 DISASSEMBLY AND ASSEMBLY FRONT FLANGE Disassembly Remove the snap ring 1 F28010 6 7 2 1 5 4 3 F28011 1 www maskinisten net Copyright...

Page 525: ...the front flange 2 Remove the seal ring 3 the O ring 4 the gasket 5 the O ring 6 and the washer 7 Assemble the washer 7 and the new O ring 6 Assemble the gasket 5 F28012 2 F29009 4 3 5 6 7 F29322 6 7...

Page 526: ...34 SECTION 27 REAR AXLE Assemble the new O ring 4 and the seal ring 3 Assemble the front flange 2 Assemble the snap ring 1 F29324 4 3 F28012 2 F28011 1 www maskinisten net Copyright...

Page 527: ...nut 1 with an appropriate hammer in order to separate the tie rod 3 from the swivel housing 2 S WARNING Don t beat on the threaded pin end of the tie rod 3 NOTE this is a destructive operation for the...

Page 528: ...od 20 Remove the rod 20 from the cylinder body 18 Remove all the seals and O rings 16 17 19 21 23 and 24 from the cylinder body 18 the cylinder head 22 and the rod 20 Assemble new seals and O rings 16...

Page 529: ...serted into the swivel housing arm 14 NOTE it is important to unscrew the locknut 12 to carry out this operation Repeat the whole sequence of the mentioned oper ations to the other side Insert the bal...

Page 530: ...38 SECTION 27 REAR AXLE REDUCTION GEAR Disassembly Drain the oil completely from the planetary carrier F27404 8 7 6 11 9 10 5 1 4 3 2 F27240 www maskinisten net Copyright...

Page 531: ...the planetary carrier cover 1 on a work bench and check its wear conditions To replace the gears if necessary remove the screw 11 and the relevant washers 8 and 9 NOTE treat the pin 10 with care Remov...

Page 532: ...e planetary carrier on a workbench and fit the gears 7 and the relevant shims 5 Insert all the rollers into the gears then position the two washers 8 and 9 NOTE the first washer must be aligned with t...

Page 533: ...1 onto the wheel hub Assemble the screws 3 and tighten to the specified torque To up the oil on the wheel hub Assemble the plug 2 onto the planetary carrier cover 1 and tighten to the specified torque...

Page 534: ...een the swivel housing 14 and the axle shaft and fit into the cardan shaft With the lever push the cardan shaft in the direction of the wheel hub to allow the removal of the snap ring S WARNING Do not...

Page 535: ...ear carrier screw in two of the just removed screws 5 into the threaded holes Remove the ring gear carrier 7 with the ring gear 4 Remove the retaining ring 8 and separate the ring gear carrier 7 from...

Page 536: ...bearing cone 12 from the swivel hous ing end using a suitable extractor Unscrew and remove the fastening bolts 19 and 17 from the upper 18 and lower 16 king pin S WARNING Before removing the king pin...

Page 537: ...hammer If it has been previously removed reassemble the steering stop composed by the screw 21 and nut 20 NOTE do not tighten the nut 20 until the steering angle adjustment has been done Force the bu...

Page 538: ...the swivel housing 14 with a belt or a rope to a hoist or to any other supporting device Protect the splined end of the axle shaft by winding it with an adhesive tape to avoid damage to the seal ring...

Page 539: ...ing end 14 Assemble the wheel hub 11 on the swivel housing 14 and fit the bearing 9 Position the ring gear carrier 7 on a workbench and force the bushes 6 to the carrier 7 surface level with the speci...

Page 540: ...es 6 using the special tool 380002667 and a hammer Apply sealant on fastening bolts 5 thread Assemble the wheel carrier 7 fastening screws 5 and tighten to the specified torque Assemble the washers 2...

Page 541: ...SECTION 27 REAR AXLE 49 CARDAN SHAFTS Disassembly Remove the cardan shaft 1 from the axle shaft 4 3 4 2 1 F27279 1 4 F27280 www maskinisten net Copyright...

Page 542: ...ARNING Be careful not to damage the bush seat Assemble the bush 3 on the axle beam with the special tool 380002226 and a hammer Assemble the seal ring 2 on the axle beam with the special tool 38000267...

Page 543: ...BODY AND BRAKES Disassembly Put alignment marks on the axle beam body and on the differential supporting flanges in order to identi fy the right side and the left side with certainty F28030 F28031 ww...

Page 544: ...en removed the brake disks are free Remove the O ring 4 Remove the disks 9 and the intermediate disks 10 Remove the gear 8 the remaining brake disk and the brake counterdisc 15 Secure the brake flange...

Page 545: ...ons Collect the brake flange 7 and place it on a work bench or fix it in a clamp Unscrew screws 11 Take from the piston 14 the springs 13 and the bushes 12 and 27 and spacer 26 Unscrew the breather 21...

Page 546: ...e fraying surface piston flange with a light layer of grease Install the piston 14 into the brake flange 7 and then a support flat disk on the piston and with a lever anchored to an eyescrew exert a p...

Page 547: ...e intermediate brake disks 10 the gear 8 and the brake counter disc 15 Assemble the new O ring 4 In order to place the axle beam correctly position the half beam 1 check the reference marks carried ou...

Page 548: ...lange being careful to the fastening holes alignment S WARNING Support the groups properly as already pointed out for disassembly phase Screw in and tighten the screws 2 of the axle shaft drum to the...

Page 549: ...isassembly Loosen the screw 4 and remove the ring nut retain er 5 Unscrew the ring nut with suitable special tool 320002218 Remove the ring nut 6 F28050 8 7 6 14 15 12 11 4 2 3 14 15 5 4 1 5 18 9 6 10...

Page 550: ...emove the bearing cups 6 Support the differential assy 2 with a rod and re move it Use an extractor to remove bearing 18 Use an extractor to remove bearing 7 F28052 6 F28053 2 F28054 18 F28055 7 www m...

Page 551: ...erential half boxes free so take care not to lower the inner compo nents Remove the ring gear 10 by means of a hammer Check the marking points 8 and 9 that will be useful during the assemblage Remove...

Page 552: ...nd the shim 11 Apply a thin layer of Molicote G n plus paste on the half housings of differential 8 and 9 S WARNING Remove rests of dope Apply a thin layer of Molicote G n plus on the gears 12 and 16...

Page 553: ...the spher ical washers 15 Assemble the gear 12 and the shim 11 Assemble the two half housings of the differential unit 8 and 9 S WARNING Carefully check that the marks of both differential half housin...

Page 554: ...ng gear 10 by means of a hammer Apply Loctite 242 on the thread of screws 1 Tighten the screws 1 to the specified torque Press the bearing 18 or assemble after preheat ing F28067 10 F27316 1 F27315 1...

Page 555: ...f the special tool 380002671 and a hammer Insert and tighten the ring nuts 6 using the wrench 380002218 until the clearance of the bearings is re moved NOTE tighten the ring nuts gradually but not exc...

Page 556: ...Loosen the screw 4 and remove the ring nut retain er 5 Unscrew the ring nut with suitable special tool 380002218 Remove the ring nut 6 F28073 8 7 6 16 15 16 15 12 11 14 13 4 2 3 15 16 17 16 15 17 5 6...

Page 557: ...he bearing cups 6 with a hammer Support the differential assy 2 with a rod and re move it Use an extractor to remove bearing 18 Use an extractor to remove bearing 7 F28052 6 F28053 2 F28054 18 F28055...

Page 558: ...ifferential half boxes free so take care not to lower the inner compo nents Remove the ring gear 10 by means of a hammer Check the marking points 8 and 9 that will be useful during the assemblage Asse...

Page 559: ...r 19 and the shim 13 Remove the shaft 17 the gears 16 and the spherical washers 15 Remove the gear 14 and the shim 13 Assemble the discs 11 and 12 19 13 F28075 15 16 15 16 17 F28076 14 13 F28077 11 12...

Page 560: ...usings of differential 8 and 9 S WARNING Remove rests of dope Apply a thin layer of Molicote G n plus on the gears 14 and 19 and on the gears 16 Assemble discs 11 and 12 Assemble the gear 14 and the s...

Page 561: ...ble the gear 19 and the shim 13 Assemble discs 11 and 12 Assemble the two half housings of the differential unit 8 and 9 S WARNING Carefully check that the marks of both differential half housings coi...

Page 562: ...ng gear 10 by means of a hammer Apply Loctite 242 on the thread of screws 1 Tighten the screws 1 to the specified torque Press the bearing 18 or assemble after preheat ing F28067 10 F27316 1 F27315 1...

Page 563: ...f the special tool 380002671 and a hammer Insert and tighten the ring nuts 6 using the wrench 380002218 until the clearance of the bearings is re moved NOTE tighten the ring nuts gradually but not exc...

Page 564: ...7 REAR AXLE PINION GROUP Disassembly In order to prevent serious damage to the pinion thread unscrew the ring nut 9 with the special tool 380000406 F28083 8 9 3 4 5 6 7 1 2 9 F29645 www maskinisten ne...

Page 565: ...terial on the splined end Remove the washer 6 the spacer 5 and the shims 4 from the pinion 1 Remove the bearing 3 from the pinion 1 using an extractor Remove the shim 2 located under the bearing and c...

Page 566: ...alse pinion 380002673 and false differential box 380002674 is used Insert the false pinion together with its bearings and its ring nut in the just mounted housings for the bearings Tighten without exc...

Page 567: ...easured value B known value 100 mm C known value 50 mm A C B X In order to determine the shim S necessary be tween the pinion and the bearing you should sub tract the V value stamped on the pinion hea...

Page 568: ...o the pinion 1 Insert the pinion 1 into its seat in the central body housing and the bearing 7 into the pinion end Insert a new washer 8 and a new ring nut 9 Screw the ring nut in using the wrench 380...

Page 569: ...the pinion taper roller bearings using a dynamometer 380002672 The adjustment is carried out by increasing the ring nut torque gradually being careful not to exceed Once you got the requested preload...

Page 570: ...S WARNING The two bars should be fixed on their middle so that they are perpendicular to the supporting surface and parallel to the pinion shaft axis align the two bars Measure the distance in mm M be...

Page 571: ...at the bars ends must be relat ed to the ratio between length of the bar and flange diameter nominal toe in A 2 measured toe in M 5 If toe in is incorrect operate with two wrenches on the guide rods...

Page 572: ...teering Adjust a protractor to the requested angle and posi tion it on the long bar Move a wheel side till it forms with the two bars the angle fixed by the protractor Adjust the mechanical steering s...

Page 573: ...nents Vehicles with wide steering angle may proceed with kicks have steering difficulty or cause pneumatic wearing at sharp turns Reduce the steering angle to minimum and decelerate when the vehicle b...

Page 574: ...ear teeth have faded Prolonged functioning at high temperatures Incorrect lubrication Low oil level Contaminated oil Replace bevel gear set Use proper lubrication fill up to right level and replace at...

Page 575: ...ncorrect lubrication Contaminated oil Use correct lubrication and fill up to right level Replace at intervals recommended Replace all scratched washers and those with a thickness by 0 1 mm lower than...

Page 576: ...bly of pinion ring nut 380002222 Assembly of bearing cups in the wheel hub 380002226 Assembly of bushing in the half beam 380002667 Assembly of bushings in the crown retaining hub 380002668 Assembly o...

Page 577: ...580SR 590SR 695SR 1 SPECIFICATIONS 3 2 PARKING BRAKE 6 2 1 PARKING BRAKE ADJUSTMENT 7 3 BRAKE CYLINDERS 8 4 OIL BRAKE TANK 13 5 BLEEDING PROCEDURE 13 SECTION 33 BRAKES SYSTEM www maskinisten net Copy...

Page 578: ...2 SECTION 33 BRAKES SYSTEM www maskinisten net Copyright...

Page 579: ...zes the brake fluid in the master cylinders which feeds the brake pistons in the axle housing The brake pistons then compress the brake friction discs and separa tion discs which locks the axle shaft...

Page 580: ...4 SECTION 33 BRAKES SYSTEM BRAKE SYSTEM LAYOUT 2WS 1 Brake piston assembly 2 Brake discs 3 Brake tank 4 Pressure switch 5 Master cylinders 6 Parking brake 7 Axle shaft www maskinisten net Copyright...

Page 581: ...SECTION 33 BRAKES SYSTEM 5 BRAKE SYSTEM LAYOUT 4WS 1 Brake piston assembly 2 Brake discs 3 Brake tank 4 Pressure switch 5 Master cylinders 6 Parking brake 7 Axle shaft www maskinisten net Copyright...

Page 582: ...n locking the drive shaft to the rear and front axles 1 Screw brake mounting 2 Assembly caliper 3 Nut brake mounting screw 4 Nut adjustment 5 Nut adjustment 6 Washer 7 Washer 8 Thrust washer 9 Lever 1...

Page 583: ...rking brake cable 3 park ing brake caliper 4 When refitting the caliper unit 2 insert the two screws 1 through the caliper It will be necessary to apply Loctite 270 to the locknuts 3 Tighten the screw...

Page 584: ...brake cylinders are linked by a balancing pipe 12 situated below the cylinders to maintain equal oil pressure between the two cylinders 1 Fitting 2 Pressure switch 3 Fitting 4 Body 5 Primary spool 6...

Page 585: ...y spool 4 Tank inlet 5 Primary spool 6 Cylinder body 7 Cylinder body 8 Primary spool stop 9 Balancing pipe 10 Oil to cylinder left hand side With the brakes released the brake lines are open to the ta...

Page 586: ...l stop 9 Balancing pipe 10 Oil to cylinder left hand side As the brake pedals are depressed initial movement of the cylinder piston closes the centre port to isolate the tank Further piston movement c...

Page 587: ...k inlet 5 Primary spool 6 Cylinder body 7 Cylinder body 8 Primary spool stop 9 Balancing pipe 10 Oil to cylinder left hand side When using one brake to assist turning the brake cylinder being applied...

Page 588: ...ousing Piston and seals 1 Piston 2 Fitting 3 Outer housing The brakes are supplied oil from the brake pedal tank and into the axle by tubes into each half axle through the fitting 2 which is sealed to...

Page 589: ...RE 1 Oil brake tank is full 1 2 Open left hand brake bleed valve 2 3 Press repeatedly on both brake pedals 3 to purge the system 4 Hold pedals down 5 Lock bleed valve 2 6 Release pedals 7 Repeat steps...

Page 590: ...14 SECTION 33 BRAKES SYSTEM NOTES www maskinisten net Copyright...

Page 591: ...PONENTS 19 2 6 DISASSEMBLY AND ASSEMBLY 20 3 CONTROL VALVES 24 3 1 CONTROL VALVES REXROTH MECHANICAL MODELS 24 3 2 REXROTH CONTROL VALVES PILOT MODELS 40 3 3 SOLENOID VALVE FOR PILOTING THE BACKHOE CO...

Page 592: ...SHIFT 99 5 10 SWING CYLINDER 103 5 11 BACKHOE ATTACHMENT SIDESHIFT CYLINDER SIDESHIFT 107 5 12 SPECIAL TOOLS 108 6 HYDRAULIC CONTROL LEVERS 109 6 1 SPECIFICATIONS 109 6 2 DESCRIPTION AND OPERATION 110...

Page 593: ...SECTION 35 HYDRAULIC SYSTEM 3 1 HYDRAULIC DIAGRAMS 1 1 HYDRAULIC DIAGRAM 2WS SIDESHIFT MECHANICAL MODELS www maskinisten net Copyright...

Page 594: ...Backhoe hammer optional 13 Hydraulic pump 14 Priority valve 15 Air filter 16 Hydraulic oil cooler 17 Diagnostic 18 Oil filter 19 Return filter 20 Backhoe attachment control valve 21 Dipper cylinder 2...

Page 595: ...SECTION 35 HYDRAULIC SYSTEM 5 1 2 HYDRAULIC DIAGRAM 2WS SIDESHIFT PILOT MODELS www maskinisten net Copyright...

Page 596: ...oe attachment control valve 21 Dipper cylinder 22 Bucket cylinder 23 Swing cylinders 24 Bi directional auxiliary 25 Boom cylinder 26 Backpressure valve 27 Telescopic cylinder 28 Stabilizer right cylin...

Page 597: ...SECTION 35 HYDRAULIC SYSTEM 7 1 3 HYDRAULIC DIAGRAM 4WS SIDESHIFT MECHANICAL MODELS www maskinisten net Copyright...

Page 598: ...nal 13 Hydraulic pump 14 Priority valve 15 Air filter 16 Hydraulic oil cooler 17 Diagnostic 18 Oil filter 19 Return filter 20 Backhoe attachment control valve 21 Dipper cylinder 22 Bucket cylinder 23...

Page 599: ...SECTION 35 HYDRAULIC SYSTEM 9 1 4 HYDRAULIC DIAGRAM 4WS SIDESHIFT PILOT MODELS www maskinisten net Copyright...

Page 600: ...rol valve 21 Dipper cylinder 22 Bucket cylinder 23 Swing cylinders 24 Bi directional auxiliary 25 Boom cylinder 26 Backpressure valve 27 Telescopic cylinder 28 Stabilizer right cylinder 29 Stabilizer...

Page 601: ...SECTION 35 HYDRAULIC SYSTEM 11 1 5 HYDRAULIC DIAGRAM 4WS CENTER PIVOT PILOT MODELS www maskinisten net Copyright...

Page 602: ...er 20 Backhoe attachment control valve 21 Dipper cylinder 22 Bucket cylinder 23 Swing cylinders 24 Bi directional auxiliary 25 Boom cylinder 26 Backpressure valve 27 Telescopic cylinder 28 Stabilizer...

Page 603: ...flow divider valve which maintains priority oil flow to the steering system with remaining flow directed for operation of stabilizers loader and backhoe elements 2 2 SPECIFICATIONS PUMP 97 HP ENGINE 1...

Page 604: ...ermittent pressure P 2 280 bar 280 bar Maximum peak pressure P 3 300 bar 300 bar Operating temperature 25 to 80 C Speed min P1 350 min 1 max P1 3000 min 1 Viscosity range recommended 12 to 100 mm 2 s...

Page 605: ...SECTION 35 HYDRAULIC SYSTEM 15 MOUNTING SCREW TORQUE HYDRAULIC DIAGRAM www maskinisten net Copyright...

Page 606: ...fice 7 Inlet port from rear pump IN 8 Steering relief valve 9 Relief valve adjuster 10 Poppet 11 Return to inlet pump port 12 Lock plug 13 Load sensing signal LS 14 Orifice When the steering is in neu...

Page 607: ...and 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 Trapped oil Return to oil tank 1 Orifice 2 Rear system...

Page 608: ...container capable of holding up to 75 litres 2 Disconnect the parking brake cable and the transmission to rear axle drive shaft 3 Disconnect and plug pump inlet and pressure hoses Remove the pump fla...

Page 609: ...at 10 Spring 11 O ring 12 Cover 13 Relief valve 14 O ring 15 Poppet 16 Spring 17 Seat 18 Rear pump body 19 Bushing 20 Gasket 21 Bushing 22 Elastic retainer 23 Bearing 24 Gear 25 Gear 26 Front pump bod...

Page 610: ...g system relief valve is disas sembled then the valve must be reset as described in the trouble shooting pressure and flow testing chapter before the vehicle is recommissioned Wash all components in a...

Page 611: ...pump body as described below Scribe an identifying letter A and B C and D on the pump housing and in the channel of each bearing block NOTE orientation of bearing block seals relative to oil port If s...

Page 612: ...e whilst observing the following Z Ensure all parts are perfectly clean and lubricate bushes and gears with clean hydraulic fluid Z Replace all seals and O rings Z Install bearing blocks into the same...

Page 613: ...ws the disassembly procedure in reverse whilst observing the following Z Ensure all parts are perfectly clean and lubricate bushes and gears with clean hydraulic fluid Z Replace all seals and O rings...

Page 614: ...r valve mounted on the pump and sends the priority flow to the steering system while the remaining flow adds to the flow from the front pump directed to the load er and backhoe attachment systems The...

Page 615: ...Hydraulic tank 2 Hydraulic pump 3 Power steering 4 Hand hammer control valve 5 Hand hammer 6 Backhoe attachment control valve 7 Loader attachment control valve 8 Backhoe hammer control valve 9 Backhoe...

Page 616: ...port in the inlet cover of the backhoe attachment control valve Because there is no load sense pressure being ap plied to the rear face of the flow balancer valve the valve will move against the sprin...

Page 617: ...27 Load sensing flow sharing All spools in neutral Pump pressure Trapped oil Return to oil tank 1 Load non return check valve 2 Load sense line 3 Pressure compensator 4 Spool 4 3 2 1 2 4 4 4 F29288 ww...

Page 618: ...alve and pump pressure in crease accordingly When pump pressure overcomes the pressure be hind the load check valve the valve opens allowing oil to flow into the cylinder port Exhaust oil from the cyl...

Page 619: ...29 Load sensing flow sharing One spool operating Pump pressure Trapped oil Return to oil tank 1 Load non return check valve 2 Load sense line 3 Pressure compensator 4 Spool 4 3 2 1 2 4 4 4 F29290 www...

Page 620: ...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...

Page 621: ...sharing Two spools operating 1st spool operating pressure 2st spool operating pressure Trapped oil Return to oil tank 1 Load non return check valve 2 Load sense line 3 Pressure compensator 4 Spool 4 3...

Page 622: ...1 loader bucket Usually the loader control valve has three valve sec tions when is installed on the loader backhoe the 4x1 bucket A 4x1 loader bucket section B Loader bucket section C Lifting section...

Page 623: ...d each hose connection to the control valve and plug the hose ends A drip tray will be required to catch oil draining from inside the hoses Z Unscrew and remove clamping screws to chassis Z Remove the...

Page 624: ...r section B Left stabilizer section C Dipper section D Bucket section E Swing section F Lifting section G Telescopic dipper section H Backhoe attachment travel lock valve sideshift 1 End cover 2 Inlet...

Page 625: ...ttery Z Clean the area around the control valve Z Tag and identify the position of all hoses Z Disconnect and plug all the hoses Z Disconnect the levers of the manual control Z Unscrew and remove clam...

Page 626: ...w balancer valve 13 the load sensing relief valve 14 and the check valve 15 from the inlet section 11 Disassembly the outlet section Sideshift version Unscrew the knob 16 Remove the solenoid 17 and th...

Page 627: ...e solutions relevant to backhoe control sections with mechanical control 1 Secondary relief valve 2 Pressure compensator 3 Check valves 4 Plug 5 Spool with spring return system 6 Spool with mechanical...

Page 628: ...with a heat gun Z Remove the adapter H the retainers I the spring J the plate K and the lip seal L Z Remove the tongue M if necessary Reassembly Z Reassemble parts in reverse order after greasing the...

Page 629: ...ing a metal rod minimum length 80 mm diam eter 6 push the central ball H while extracting the detent bush I Z Mark the orientation of the detent bush for the reas sembly Z Remove the balls J and the s...

Page 630: ...in the cab a control valve is driven that on its turn drives hydraulically the back hoe control valve monitoring the backhoe loader and the stabilizers The backhoe loader with hydraulic control is equ...

Page 631: ...4 Hand hammer control valve 5 Hand hammer 6 Backhoe attachment control valve 7 Loader attachment control valve 8 Backhoe hammer control valve 9 Backhoe hammer 10 Oil cooler 11 Return line distributor...

Page 632: ...1 loader bucket Usually the loader control valve has three valve sec tions when is installed on the loader backhoe the 4x1 bucket A 4x1 loader bucket section B Loader bucket section C Lifting section...

Page 633: ...each hose connection to the control valve and plug the hose ends A drip tray will be required to catch oil draining from inside the hoses Unscrew and remove clamping screws to chassis Remove the valve...

Page 634: ...lizer section B Left stabilizer section C Dipper section D Bucket section E Swing section F Lifting section G Telescopic dipper section H Backhoe attachment travel lock valve sideshift 1 End cover 2 I...

Page 635: ...he battery Clean the area around the control valve Tag and identify the position of all hoses and hydrau lic tubes Disconnect and plug all the hoses and all the hy draulic tubes Unscrew and remove cla...

Page 636: ...w balancer valve 13 the load sensing relief valve 14 and the check valve 15 from the inlet section 11 Disassembly the outlet section Sideshift version Unscrew the knob 16 Remove the solenoid 17 and th...

Page 637: ...ndicated all possible solutions rel evant to backhoe control valve sections with hydrau lic control 1 Secondary relief valve 2 Pressure compensator 2A Pressure compensator with shock absorber 2B Fixed...

Page 638: ...w seals E Z Install the cap assemblies on the valve section in stall and tighten the screws A to a torque of 9 to 11 Nm Electrical detent system spool Solenoid replacement with spool pulled out Z Remo...

Page 639: ...with the pilot models and has the task to transform the electrical controls received from the hydraulic control levers in hydraulic controls and to send them to the backhoe attachment control valve Th...

Page 640: ...ngine and relieve any residual pressure in the backhoe and loader attachment systems by moving the relevant control levers through all oper ating positions Z Disconnect the battery Z Clean the area ar...

Page 641: ...blocks Loosen and remove the screws 6 Disassemble the solenoid valves 7 Check and eventually replace the O rings 8 Loosen and remove the valve 9 Check and eventually replace the O rings 10 Remove the...

Page 642: ...f valve 2 Loader bucket relief valve rod end 240 bar 3 Hydraulic speed relief valve 165 bar 4 Loader bucket relief valve piston end 165 bar Some of them are installed on the backhoe control valve 1 Di...

Page 643: ...and valve body causing a pressure differential between the front and rear face of the poppet valve The higher pres sure in the cylinder supply gallery unseats the poppet valve and moves the piston to...

Page 644: ...a void created in the piston end This oil is auto matically replenished by the anti cavitation device in the opposite circuit relief valve as follows The void creates a pressure lower in the cylinder...

Page 645: ...ppet 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...

Page 646: ...nation they may be disassembled and in spected for wear However remember to restore the correct pressure The relief valves contain no serviceable components with the exception of the external O rings...

Page 647: ...dy 2 Poppet 3 Spring 4 Spring 5 Shim 6 Cover 7 O ring 8 Nut 9 O ring 10 Adjuster screw Loader bucket relief valve 1 Relief valve assembly 2 Spring 3 Nut 4 Body 5 Adjuster screw 6 Spring 7 Piston 8 Pop...

Page 648: ...opriate port in the test block as follows A Stabilizer and backhoe relief valves B Loader bucket relief valves C Unload valve NOTE a special removable insert which is part of the test block is install...

Page 649: ...urized to 170 bar Using the special spanner supplied loosen the lock nut on the end of the valve and adjust pressure set ting using Allen wrench Operate hand pump and recheck pressure When pressure se...

Page 650: ...umulator 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 bot...

Page 651: ...apter insert 5 Pressure gauge 6 Protective cap gauge port 7 Collar gas port 8 Knurled protective cap filling port 9 Hose G1 4 fitting 60 cone with O ring 10 Valve Z Remove the protective cover and cap...

Page 652: ...nflation valve A by screwing the handwheel counterclockwise Z Remove the cap 8 Z Connect the end of the hose 9 to the valve 10 Z Connect the other end of the hose to the nitrogen source Z Progressivel...

Page 653: ...t the main chassis of 180 de grees This movement is obtained by the use of two hydrau lic cylinders 1 coupled between the main chassis and swing post The cylinders act directly on the swing post witho...

Page 654: ...and back to tank The spool in the swing control valve assembly 1 is designed such that during operation oil can flow freely through the port directing oil flow to the swing cylinders but restricts th...

Page 655: ...ted return oil 2nd stage restricted return oil Return to oil tank 1 Control valve swing section 2 One way restrictor 3 Cushioning rod 4 Right hand cylinder 5 Left hand cylinder 6 Cushioning rod 7 One...

Page 656: ...loader bucket cylinder 4 Backhoe boom cylinder 5 Backhoe dipper cylinder 6 Backhoe bucket cylinder 7 Telescopic cylinder 8 Swing backhoe cylinder 9 Stabilizer cylinder center pivot models 10 Stabilize...

Page 657: ...SECTION 35 HYDRAULIC SYSTEM 67 5 1 LOADER ATTACHMENT BOOM CYLINDER 2WS 1 Stroke 2 Completely retracted 4WS 1 Stroke 2 Completely retracted www maskinisten net Copyright...

Page 658: ...ader is fully supported Do not work under or near an unsupported loader or personal in jury may occur Relieve the residual pressure in the system by mov ing the loader control lever through all operat...

Page 659: ...SECTION 35 HYDRAULIC SYSTEM 69 Remove the ring 3 and the pin 4 Use a hammer to extract the rod pin 5 Remove the loader attachment boom cylinder www maskinisten net Copyright...

Page 660: ...n gasket 13 Piston guide 14 Screw 15 Cylinder tube 16 Bushing The disassembly procedure below starts on the premise that the hydraulic lines have already been removed S WARNING Cylinder weight 2WS 32...

Page 661: ...stic hammer Remove the cylinder rod 1 and the cylinder head 7 IMPORTANT be sure to pull the cylinder rod 1 straight so as not to damage the sliding surfaces Loosen and remove the screw 14 Extract the...

Page 662: ...72 SECTION 35 HYDRAULIC SYSTEM 5 2 LOADER BUCKET CYLINDER 2WS 1 Stroke 2 Completely retracted 4WS 1 Stroke 2 Completely retracted www maskinisten net Copyright...

Page 663: ...g the loader control lever through all operating po sitions Support the cylinder using sling and suitable hoist Disconnect the hydraulic hoses Support the link rods Remove the snap ring 1 with the spa...

Page 664: ...Piston gasket 12 Piston guide 13 Screw 14 Cylinder tube 15 Bushing The disassembly procedure that follows takes into consideration the hydraulic piping already disas sembled S WARNING Cylinder weight...

Page 665: ...it with a plastic hammer Remove the cylinder rod 2 and the cylinder head 6 IMPORTANT be sure to pull the cylinder rod 2 straight so as not to damage the sliding surfaces Loosen and remove the screw 13...

Page 666: ...Bucket 4 Cylinder 5 Dowel 6 Nut 7 Cylinder bottom pin CYLINDER REMOVAL Park machine on a flat surface and position the bucket firmly on the ground Relieve the residual pressure in the system by mov i...

Page 667: ...d 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 ha...

Page 668: ...CTION 35 HYDRAULIC SYSTEM DISASSEMBLY CYLINDER 1 Cylinder tube 2 Piston 3 Pin 4 O ring 5 Piston guide 6 O ring 7 Cylinder head 8 Gasket 9 Wiper ring 10 Cylinder rod 11 Bushing www maskinisten net Copy...

Page 669: ...ele ments for cylinder removal using a suitable stand S WARNING Always support the structural members so that they will be stable and safe to work around Stop the engine and move the backhoe attachmen...

Page 670: ...e pin 2 only partially then remove the cylin der rod and finally reinsert the pin If necessary use hydraulic power to very slowly re tract the cylinder In this way the rod moves away from the attachin...

Page 671: ...3 Piston gasket 14 Piston 15 Piston gasket 16 Washer 17 Screw 18 Cylinder tube 19 Bushing 20 Wiper ring The disassembly procedure that follows takes into consideration the hydraulic piping already dis...

Page 672: ...e the cylinder rod 3 and the cylinder head 9 IMPORTANT be sure to pull the cylinder rod 3 straight so as not to damage the sliding surfaces Loosen and remove the screw 17 with the relevant washer 16 E...

Page 673: ...ckhoe ele ments for cylinder removal using a suitable stand S WARNING Always support the structural members so that they will be stable and safe to work around Stop the engine and move the backhoe att...

Page 674: ...ay the rod moves away from the attaching point Disconnect the hydraulic hoses Loosen and remove the screw 4 Slide out the rod pin 5 with an ham mer The tube end of the dipper cylinder and rod end of t...

Page 675: ...on gasket 13 Piston guide 14 Piston 15 Washer 16 Screw 17 Cylinder tube 18 Bushing 19 Wiper ring The disassembly procedure that follows takes into consideration the hydraulic piping already disas semb...

Page 676: ...c hammer Remove the cylinder rod 3 and the cylinder head 9 IMPORTANT be sure to pull the cylinder rod 3 straight so as not to damage the sliding surfaces Loosen and remove the screw 16 with the washer...

Page 677: ...irmly on the ground S 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 opera...

Page 678: ...in 3 with an hammer and pay attention to le vers If necessary use hydraulic power to very slowly re tract the cylinder Disconnect the hydraulic hoses Unscrew and re move the screw 4 and slide out the...

Page 679: ...Piston gasket 13 Piston guide 14 Piston 15 Screw 16 Cylinder tube 17 Bushing 18 Wiper ring The disassembly procedure that follows takes into consideration the hydraulic piping already disas sembled S...

Page 680: ...stic hammer Remove the cylinder rod 3 and the cylinder head 9 IMPORTANT be sure to pull the cylinder rod 3 straight so as not to damage the sliding surfaces Loosen and remove the screw 15 Extract the...

Page 681: ...le ments for cylinder removal using a suitable stand S 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...

Page 682: ...Disconnect the hydraulic hoses 3 at dipper cylin der and support cylinder using suitable hoist Remove the snap ring 5 Hammer to slide out the pin 4 from the other side Remove the telescopic cylinder...

Page 683: ...Piston gasket 11 Piston guide 12 Piston 13 Screw 14 Cylinder tube The disassembly procedure that follows takes into consideration the hydraulic piping already disas sembled S WARNING Cylinder weight...

Page 684: ...ith a plastic hammer Remove the cylinder rod 1 and the cylinder head 7 IMPORTANT be sure to pull the cylinder rod 1 straight so as not to damage the sliding surfaces Loosen and remove the screw 13 Ext...

Page 685: ...backhoe loader is locked in the transfer position or parked in a safety work position Lower the stabilizers to the ground Support the cylinder safely with suitable belt and hoist Remove the snap ring...

Page 686: ...stopped release any residual pressure by moving the control levers of stabilizers Disconnect all hydraulic hoses Remove the snap ring 4 and the shim 5 Hammer to slide out the pin 6 Remove the stabili...

Page 687: ...9 O ring 10 Piston gasket 11 Piston guide 12 Piston 13 Screw 14 Cylinder tube The disassembly procedure that follows takes into consideration the hydraulic piping already disas sembled S WARNING Cylin...

Page 688: ...ith a plastic hammer Remove the cylinder rod 1 and the cylinder head 7 IMPORTANT be sure to pull the cylinder rod 1 straight so as not to damage the sliding surfaces Loosen and remove the screw 13 Ext...

Page 689: ...flat surface and position the bucket on the ground Lower the stabilizers to the ground Relieve possible residual pressures in the system by moving the loader attachment control lever through all oper...

Page 690: ...ect the hydraulic tubes at the top of the sta bilizer Remove the snap ring 4 and extract the pin 5 Screw in an eye screw 6 on the cylinder and con nect a rope or a chain Lift and remove the stabilizer...

Page 691: ...guide 11 Piston gasket 12 Screw 13 Cylinder tube The disassembly procedure that follows takes into consideration the hydraulic piping already disas sembled S WARNING Cylinder weight 34 5 kg Lift and...

Page 692: ...with a plastic hammer Remove the cylinder rod 1 and the cylinder head 5 IMPORTANT be sure to pull the cylinder rod 1 straight so as not to damage the sliding surfaces Loosen and remove the screw 12 Ex...

Page 693: ...ARNING 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 re li...

Page 694: ...turn 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 cyl...

Page 695: ...iston gasket 14 Piston guide 15 Piston 16 Lock retaining piston 17 Cylinder tube The disassembly procedure that follows takes into consideration the hydraulic piping already disas sembled S WARNING Cy...

Page 696: ...omplete with gaskets Check the bushings 8 status Only if necessary Z remove the wiper ring 4 the seal rings 5 and 6 the guide bush 7 and the back up ring 12 with the O ring 11 from the king pin 10 Z r...

Page 697: ...ts of 1 Body 2 Cylinder 3 Seals CYLINDER REMOVAL Park machine on a flat surface and position the bucket on the ground Position the backhoe support in the centre of the ma chine and lower the backhoe o...

Page 698: ...ead Stabilizer cylinder head sideshift 380000722 Wrench Loader bucket cylinder head 380000724 Wrench Backhoe boom cylinder head Backhoe dipper cylinder head 380000725 Wrench Backhoe bucket cylinder he...

Page 699: ...IONS Weight 5 1 5 3 kg Spool stroke 7 55 mm SPECIAL TORQUE SETTINGS Maximum permissible on the hydraulic control lever 80 Nm Control block retaining screw 30 Nm Control block universal joint 50 Nm Con...

Page 700: ...abilizer 5 CONTROL PATTERN CHANGE SWITCH this switch is used for changing the standard control pattern to the ISO pattern 6 TELESCOPIC DIPPER CONTROLS propor tional controls If fitted Press the right...

Page 701: ...DRAULIC CONTROL LEVER 1 Valve 2 Plate 3 Screw 4 Nut 5 Boot 6 Connector 7 Wedge 8 Half handle 9 Screw 10 Half handle 11 Cover 12 Switches 13 Washer 14 Spacer 15 Clip 16 Clip 17 Plugs if the switches 12...

Page 702: ...crew 4 Nut 5 Boot 6 Connector 7 Wedge 8 Half handle 9 Screw 10 Half handle 11 Cover 12 Switch push button horn 13 Washer 14 Spacer 15 Clip 16 Clip 17 Plugs if the switches 18 are not fitted 18 Switch...

Page 703: ...osition Move both joysticks in all directions Turn the starter switch key to OFF Disconnect the negative battery cables Z Mark the position of the lever parts see the explod ed view on previous pages...

Page 704: ...h relevant connectors Q1 with right control lever Z Remove the knob P1 in the rear section of control lever Z Remove the screws V and the plate N Z Lift the rubber boot RL for left control lever and t...

Page 705: ...column Z Remove the screws 9 Separate the half handles 8 and 10 Remove the cap 11 Unscrews the nut 4 and remove the screw 3 Remove the spacers 14 Remove the boots 5 Remove the plate 2 Reassembly To re...

Page 706: ...ply T Return to tank Right valve dipper bucket 1 Retracting the dipper 2 Opening the backhoe bucket 3 Extending the dipper 4 Closing the backhoe bucket Left valve backhoe swing 1 Lifting 2 Right swing...

Page 707: ...int cam 2 Plate 3 Shim 4 Upper body 5 Rod guide 6 Ring seal 7 Ring seal 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...

Page 708: ...e upper body 4 in a vice 14 Loosen and remove the screw 17 using a key and replace the O ring 18 15 Separate the upper 4 and lower 19 bodies and replace the seal rings 20 and 21 Reassembly 1 To reasse...

Page 709: ...igns of external damage that might cause gross misalignment of structural members Z Check in more detail for other mechanical damage such as kinked twisted worn or decayed hoses damaged cylinders and...

Page 710: ...ool leakage Piston seals leaking or cylinder barrel damaged Examine lift section of loader control valve assembly for wear or scoring Examine reseal piston and gland Bucket fails to operate is slow or...

Page 711: ...ressure of the digging system relief valve Examine digging section of backhoe control valve assembly for wear and scoring Examine reseal piston and gland The digging control fails to operate is slow o...

Page 712: ...emble and inspect Examine reseal piston and gland 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 lo...

Page 713: ...d top up Hydraulic oil drain through tank breather Tank overfilled Aeration air entering the system at suction tube pump shaft fittings or cylinder ring nuts Cavitation Restriction of the suction filt...

Page 714: ...124 SECTION 35 HYDRAULIC SYSTEM NOTES www maskinisten net Copyright...

Page 715: ...ND INSTALLATION COMPONENTS 5 2 1 COMPONENTS WITHIN THE CHASSIS 5 2 2 COMPONENTS BELOW THE CHASSIS 6 2 3 COMPONENTS ATTACHED OUTSIDE THE CHASSIS 8 2 4 COMPONENTS ATTACHED ON THE CHASSIS 9 2 5 MOUNTING...

Page 716: ...2 SECTION 39 CHASSIS www maskinisten net Copyright...

Page 717: ...the kind of backhoe attach ment that the backhoe loader should carry Z Center pivot means that the backhoe is connected directly to the chassis and cannot shift laterally only for 4WS Z Sideshift mea...

Page 718: ...4 SECTION 39 CHASSIS CENTER PIVOT 4WS CHASSIS SIDESHIFT 2WS CHASSIS SIDESHIFT 4WS CHASSIS www maskinisten net Copyright...

Page 719: ...of the engine and supported in rubber silent blocks in fixed brackets and held within the frame just at the rear of the loader post To make repairs that require disassembly of the transmission or engi...

Page 720: ...ing bolts 4WD Z Disconnect the spider coupling 4WD Z Remove the axle bolts Z Remove the front axle REAR AXLE The rear axle is attached to the frame at the rear of the machine by 4 through bolts To rem...

Page 721: ...ECTION 39 CHASSIS 7 COUNTERWEIGHT Counterweight is installed under the chassis in the front section of the machine with two bolts The weight of the counterweight 1 160 kg www maskinisten net Copyright...

Page 722: ...the right hand side of the machine and the fuel tank 2 mounted to the left hand side of the machine Both tanks when drained of their contents can be re moved from the machine by removal of the attach...

Page 723: ...CHASSIS CAB A Front fixing B Rear fixing S Cab skirts 1 Main frame 2 Anti vibration 3 Dampener 4 Washer 5 Washer 6 Nut 7 Retaining screw 8 Washer 9 Cab floor 10 Cab support rear 11 Support 12 Bushing...

Page 724: ...ect the pump power steering valve hose Z Disconnect the power steering valve oil tank hose Z Disconnect the load sensing valve hose Z Disconnect the stabilizers cables mechanical ver sion Z Disconnect...

Page 725: ...s to frame 95 Nm Radiator retaining bolts to frame 95 Nm Front cardan joint to axle 38 Nm Front cardan joint to transmission 38 Nm Rear cardan joint to axle 38 Nm Rear cardan joint to transmission Pow...

Page 726: ...aining clamps 52 Nm Boom to swing support 320 Nm Stabilizers upper pins retaining bolt 80 Nm Fastening pin of boom cylinder 320 Nm Fastening pin of dipper cylinder 320 Nm Fastening pin of bucket cylin...

Page 727: ...ING SYSTEM 2WS 4 2 STEERING SYSTEM 4WS 7 3 POWER STEERING 12 3 1 SPECIFICATIONS 13 3 2 COMPONENTS 15 3 3 DISASSEMBLY AND ASSEMBLY 16 3 4 SPECIAL TOOLS 33 3 5 FAULT FINDING 33 SECTION 41 STEERING SYSTE...

Page 728: ...2 SECTION 41 STEERING SYSTEM www maskinisten net Copyright...

Page 729: ...to the loader and backhoe control valves and side shift clamping sys tem Rear pump flow passes through the flow divider valve which maintains priority oil flow to the steer ing system with remaining f...

Page 730: ...ION 41 STEERING SYSTEM 1 STEERING SYSTEM 2WS COMPONENTS 1 Flow divider 2 Power steering 3 Hydraulic tank 4 Return manifold 5 Oil filter 6 By pass valve 7 Radiator 8 Front axle www maskinisten net Copy...

Page 731: ...he leaf springs return and hold the power steering spool in the neu tral position This ensures no more oil is supplied to the steering cylinder The spool also traps the oil in the steering cylinder an...

Page 732: ...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 sens ing line to the priority flow divider As the metering unit is turned b...

Page 733: ...TEERING SYSTEM 4WS COMPONENTS 1 Flow divider hydraulic pump 2 Power steering 3 Hydraulic tank 4 Return manifold 5 Oil filter 6 By pass valve 7 Radiator 8 Front axle 9 Steering control valve 10 Rear ax...

Page 734: ...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 solen...

Page 735: ...EERING VALVE DIAGRAM In the position shown both spools have been moved by solenoids 2b and 3b The detents on the a side of the solenoid hold the spool in this position until another solenoid is pulsed...

Page 736: ...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 valv...

Page 737: ...wheel steer Front and rear wheel crab The solenoids energized are shown in the table be low These are also the pins which need to be pressed when changing steering mode manually in an emer gency X Ene...

Page 738: ...rotor The selection rotor is connected to the steering wheel through column that can be of two types fixed or adjustable Z A cardan shaft mechanically tied to gear wheel as sembly and to outer sleeve...

Page 739: ...ment 2WS 200 220 bar Shock valve adjustment 4WS 240 260 bar 3 4 16 UNF Nm 60 7 16 20 UNF Nm 20 Steering wheel nut Nm 55 Steering motor to steering column bracket Nm 23 Power steering end cover Nm 30 P...

Page 740: ...14 SECTION 41 STEERING SYSTEM HYDRAULIC DIAGRAM 1 Power steering 2 Power steering control valve 3 Check valve 4 Anti shock valve set at 240 260 bar 5 Anticavitation valve www maskinisten net Copyright...

Page 741: ...shing 5 O ring 6 Bearing 7 Ring 8 Cross pin 9 Cardan shaft 10 Set of springs 11 O ring 12 Distributor plate 13 Rotor stator gear 14 O ring 15 End cover 16 Washer 17 Special screw 18 Screw 19 Body 20 B...

Page 742: ...t the four connectors and collect the O ring seals noting the connector positions Remove the four screws from within the cab The power steering can be removed from the front of the cab through the eng...

Page 743: ...TEERING SYSTEM 17 Remove the end cover 15 Extract the rotor stator gear 13 with spacer if fit ted Extract the two O rings 14 Remove the cardan shaft 9 Remove the distributor plate 12 www maskinisten n...

Page 744: ...valve pins 21 and the balls 20 Replace the pins 21 prior to the reassembly Take care to keep the cross pin in the sleeve and spool horizontal The pin can be seen through the open end of the spool Pres...

Page 745: ...Use the special screw 17 A small mark has been made with a pumice stone on both spool and sleeve close to one of the slots for the neutral position springs see drawing If the mark is not visible remem...

Page 746: ...emove the seal ring 24 and the O ring 5 Remove the plugs from the shock valves using a 6 mm hexagon socket spanner Remove the seal washers Unscrew the setting screws using a 6 mm hexagon socket spanne...

Page 747: ...signs of wear in the following areas Z Rotor and stator of metering unit move freely Z Check the drive pin is not cracked or bent Z Check the rollers in thrust bearing are free to ro tate Z Ensure th...

Page 748: ...e the two flat neutral position springs in the slot Place the curved springs between the flat ones and press them into place Line up the spring set 10 Guide the spool 2 into the sleeve 1 Make sure tha...

Page 749: ...sleeve in the end of the spool sleeve op posite to the end with spring slots Place the slots and holes opposite each other so that parts of the holes in the sleeve are visible through the slots in the...

Page 750: ...drawing 1 Spool 2 Sleeve 6 Bearing needle 6A Outer bearing race 6B Needle bearing 6C Inner bearing race The inside chamfer on the inner bearing race must face the inner spool Turn the steering unit un...

Page 751: ...ssembly tool in the bottom of the steering unit housing and guide the inner part of the tool right to the bottom Press and turn the O ring into position in the hous ing Draw the inner and outer parts...

Page 752: ...and place it on the assembly tool Guide the assembly tool right to the bottom Press and turn the seal ring into the housing With a light turning movement guide the spool and sleeve into the bore Fit t...

Page 753: ...ring unit until the bore is vertical again Put the check valve ball 3 into the hole indicated in the picture Screw the threaded bush 4 lightly into the check valve bore The top of the bush must lie ju...

Page 754: ...holes Grease the O ring 11 with mineral oil Position the distributor plate 12 so that the channel holes match the holes in the housing Guide the cardan shaft 9 down into the bore so that the slot is...

Page 755: ...place them in the two grooves in the gear rim Insert the rotor stator gear and the rim on the cardan shaft Fit the gearwheel rotor and cardan shaft so that a tooth base in the rotor is positioned in...

Page 756: ...valve pay attention to the parallelism of A B C and D reference marks A Rotor stator surface B Distributor plate surface C Pin axis D Housing surface E Rotor gear F Cardan shaft Position the end cover...

Page 757: ...hers 16 Cross tighten all the screws and the roller pin to a torque of 30 6 Nm in the sequence shown The in itial torque is 10 8 Nm Put a ball in the two holes Place springs and valve cones over the t...

Page 758: ...with seal ring into the two shock valves and tighten them with a torque of 30 10 Nm Position the seal ring 24 into the housing Install the seal ring into the housing using the special tool and a plas...

Page 759: ...ck the system pressure Inspect and repair Inspect and repair Inspect and replace Inspect and replace Steering wanders Excessive clearance in the ball joints of the steering connecting rods Leaking pow...

Page 760: ...34 SECTION 41 STEERING SYSTEM NOTES www maskinisten net Copyright...

Page 761: ...IR CONDITIONING 12 3 2 SAFETY PRECAUTIONS 16 3 3 CONTROLS AND OPERATION 17 3 4 FAULT FINDING AND TESTING 26 3 5 FLUSHING THE SYSTEM 44 3 6 EVACUATING THE SYSTEM 46 3 7 CHARGING THE SYSTEM 47 3 8 COMPO...

Page 762: ...2 SECTION 50 CAB HEATING AND AIR CONDITIONING www maskinisten net Copyright...

Page 763: ...95 C Radiator cap 0 90 bar TORQUE VALUES Coolant hot water hose connections 5 Nm Air hose ducting connections 5 Nm Heater housing to floor mounting bolts 6 2 Nm Refrigerant HFC 134a Refrigerant charg...

Page 764: ...3 bar PERFORMANCE CALCULATED AT 2 0 m s 383 4 m3 h Exchanged warmth 9 29 kW 7998 69 kcal h Air outlet temperature 10 30 C Air side load loss 9 34 daPa 0 95 mmH20 Coolant side load loss 32 7 kPa 0 33 b...

Page 765: ...e the temper ature S WARNING The cab air filters are designed to remove dust from the air but may not exclude chemical vapour When working in an enclosed area ensure there is ade quate ventilation as...

Page 766: ...motor to direct warm or cold air onto the windscreen and side windows or to the cab interior as required Each vent may be swivelled and adjusted to control the flow of air To open a vent press one si...

Page 767: ...r housing 2 Air ducting to the front windscreen 3 Radiator hoses of the heater control panel 4 Air ducting to the rear windscreen below the cab floor 5 Air intake to the heater housing from below the...

Page 768: ...he cock normal operation and is not to be considered as a fault Release of the electrical heater valve IMPORTANT the release of the valve has to be per formed if this valve remains idle for long perio...

Page 769: ...k the seal condition Clean or replace the filter Replace the filter Repair and Seal air leak s Blower motor air flow low Blocked filter or recirculation filter Heater radiator core blocked Clean or re...

Page 770: ...the en gine oil filter mounted to the left hand side of the en gine Heater radiator With the system drained remove the heater radiator hose connections attaching bolts and remove from the vehicle Ins...

Page 771: ...the hoses and the control cable and remove Check the opera tion of the valve and if tight or worn replace Heater control panel The blower motor is operated by a 3 position switch 3 which through a va...

Page 772: ...en two bodies of different temperature come together heat is transferred from one to another On air conditioning systems an evaporator is used to hold the low temperature refrigerant which absorbs the...

Page 773: ...through an orifice the temperature of the resultant vapour will lower The low temperature of the atomized liquid will then absorb heat from its surrounding On air conditioning systems the refrigerant...

Page 774: ...Expansion valve atomizes liquid refrigerant be fore passing to evaporator 2 Evaporator absorbs heat from air in cab 3 Compressor compresses and raises tempera ture of refrigerant gas 4 Condenser and...

Page 775: ...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 gi...

Page 776: ...ed with care in order to AVOID HAZARDS Undue direct contact with liquid refrigerant can pro duce freezing of skin and eyes Keep the refrigerant container and air conditioning system away from flame or...

Page 777: ...t set to the stop posi tion Turn the selector 4 for air capacity according to your requirements CONTROLS 580SR 590SR 695SR The air conditioning control can be adjusted to obtain the desired temperatur...

Page 778: ...ections regarding protec tion from dangerous chemicals If the machine has been parked in the sun quicken the cooling by operating the air conditioning for 2 3 minutes at its coldest setting Set maximu...

Page 779: ...truments or attachments previously used with R12 as the system could get damaged HFC 134a refrigerant is stable at all operating tem peratures and able to absorb great quantities of heat The boiling p...

Page 780: ...gear engaging with teeth formed in the face of the plate The seven pistons are connected to the wobble plate by rods located in ball sockets Refrigerant is drawn in on the downward stroke of a piston...

Page 781: ...ol switch The switch upon comparing the two voltages deter mines whether the compressor clutch should be switched on or off in order to maintain the desired in cab temperature control Low pressure cut...

Page 782: ...the re ceiver drier where it is filtered and desiccated to re move any moisture before passing through an outlet line to the thermostatic expansion valve RECEIVER DRYER The receiver dryer 2 situated b...

Page 783: ...r these purposes The refrigerant from the condenser and receiver dry er enters the thermostatic expansion valve as a high pressure warm liquid Upon passing through the ball and spring controlled meter...

Page 784: ...by the refrigerant the pressure of the gas in creases causing a differential pressure above and below the temperature sensor diaphragm The dia phragm reacts to this pressure differential and a push ro...

Page 785: ...recircula tion grille 1 The air passes over the evaporator then into the cab through the six louvered vents Two vents are located on the front instrument panel to direct air onto the windshield Two a...

Page 786: ...ding lubricating oil to the system always uncap and re cap the oil container immediately be fore and after use Always ensure the oil remains free of moisture Preliminary fault finding Always conduct t...

Page 787: ...l 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 testi...

Page 788: ...and doors 2 Re check that both the high and low side shut off valves on the manifold gauge set are fully closed 3 Run the engine at 1000 1200 rpm 4 Turn the heater temperature control OFF 5 Operate t...

Page 789: ...ak tests and repair Evacuate the system Charge system re test system Evaporator air cool but not sufficiently cold Low pressure switch cutting out Expansion valve to evaporator tube shows considerable...

Page 790: ...ngine Recover and recycle the charge using correct recovery equipment Recharge the system with the correct quantity of refrigerant replacing any lost lubricant Recheck performance of air conditioning...

Page 791: ...r Evacuate the system Charge the system Re test PROBLEM POSSIBLE CAUSE CORRECTION Insufficient cooling Low pressure reading does not fluctuate with changes in temperature control switch pressure shoul...

Page 792: ...ce connector 6 Low side hand valve closed 7 Low side low PROBLEM Little or no cooling CAUSE Refrigerant slightly low CONDITIONS Low side pressure too low Gauge should read 1 2 bar High side pressure t...

Page 793: ...2 bar High side pressure too low Gauge should read 13 3 14 8 bar Evaporator air warm Low pressure switch cutting out CORRECTIVE PROCEDURES 1 Leak test the system 2 Discharge and recover the refrigera...

Page 794: ...ure slightly high or slightly low Gauge should read 13 3 14 8 bar Evaporator air not cold CORRECTIVE PROCEDURES 1 Leak test the system Give special attention to the compressor seal area 2 Discharge an...

Page 795: ...cooling CAUSE Compressor malfunction CONDITIONS Low side pressure too high Gauge should read 1 2 bar High side pressure too low Gauge should read 13 3 14 8 bar Evaporator air not cold CORRECTIVE PROCE...

Page 796: ...and coil or other obstructions that could reduce condenser airflow 3 If engine is overheating replace engine thermo stat and radiator pressure cap At this point operate the system and check its per f...

Page 797: ...Gauge should read 1 2 bar High side pressure too low Gauge should read 13 3 14 8 bar Evaporator air not cold CORRECTIVE PROCEDURES 1 Discharge and recover the refrigerant from the system 2 Replace rec...

Page 798: ...mpressor sur faces show considerable moisture CORRECTIVE PROCEDURES 1 Check for sticking expansion valve as follows Operate the system at maximum cooling Check the low side gauge The pressure should l...

Page 799: ...le moisture or frost Low pressure switch cutting out CORRECTIVE PROCEDURES 1 Place finger on expansion valve to evaporator tube If too cold to touch proceed as follows Operate the system at maximum co...

Page 800: ...small Evaporator only slightly cool Liquid line and receiver dryer are cool to touch and show frost or considerable moisture CORRECTIVE PROCEDURES 1 Check for sticking expansion valve as follows Oper...

Page 801: ...uring both ON and OFF compressor cycles and between cycles Readings should be 0 8 1 0 bar cycle OFF 2 5 2 7 bar cycle ON 1 7 1 9 bar between cycles High side pressure normal Gauge should read 13 3 14...

Page 802: ...00 g of refriger ant Z Check system for leaks Z Fully charge the system Always check the system for leaks as a final test af ter evacuating and before recharging Refer to Evacuating the system Dischar...

Page 803: ...g recovery equipment 1 Run the vehicle s air conditioning system for a few minutes 2 Set up the recovery unit following manufactur er s instructions Ensure that the units red high side hose is connect...

Page 804: ...em 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 Flus...

Page 805: ...han a special flush solvent made specifically for air conditioning systems Al ways follow the manufacturer s recommendations and directions for using the flushing equipment and solvent Re assemble and...

Page 806: ...nstructions Fully open both the low and high side gauge shut off valves 2 If a combined recovery evacuation unit is to be used attach the unit to the air conditioning sys tem in accordance with the ma...

Page 807: ...itioning so that the compressor can pull the remainder of the refrigerant into the sys tem 5 If the refrigerant charge will not completely transfer to the air conditioning system recover and recharge...

Page 808: ...must then be added to the new item before being installed onto the loader backhoe Upon completion of the repair evacuate recharge leak test and performance test the system to ensure correct operation...

Page 809: ...leakage If damage or leaks are ev ident replace the evaporator core If a new evaporator is to be installed drain the refrig erant oil in the evaporator into a clean calibrated container Measure the qu...

Page 810: ...r wiring connector block 3 Remove the remaining motor securing screws and withdraw motor 4 Re assembly follows the disassembly procedure in reverse RECEIVER DRYER The receiver dryer 3 cannot be overha...

Page 811: ...ve the front grill 1 2 Unscrew and remove the nut 3 Remove the horn 4 Unscrew and remove the nut 5 Re move the fuel cooler 6 3 Unscrew and remove the fixing upper nut 7 and loosen the fixing lower nut...

Page 812: ...rom the un derside of the filter 2 Remove the filter and clean it by blowing with compressed air not exceeding 2 bar IMPORTANT make sure you protect your face be fore using compressed air Blow the dus...

Page 813: ...ssor and pulley 0 9 0 8 mm Belt tension Measure at the widest gap 10 mm deflection with 1 kg force applied midway between the pulleys Speed rating Tightening torques MAXIMUM RPM Constant Downshift 600...

Page 814: ...leak Intermittent or inoperative Check belt tension Check clutch air gap Check clutch volts amps coil lead wire Replace Adjust air gap Replace or repair Broken lead wire Clutch coil defect Internal S...

Page 815: ...onnect the electrical harness of the compressor 12 from the electrical harness of the engine Disconnect tub ing to compressor Remove the washer 7 and the screw 1 Remove the protective guard 13 Re move...

Page 816: ...r if the old compressor is to be refitted obtain a new can of refrigerant oil Z Calculate the amount of oil to be installed and refill the compressor Z Reconnect the hoses to the compressor and tight...

Page 817: ...from the compressor Z Remove the oil plug and drain as much oil as pos sible into a suitable container Z Remove the caps if present from suction and dis charge ports Z Drain oil from the section and d...

Page 818: ...f the clutch plate and placing a socket and ratchet through the tool remove the cover attaching nut 3 Using the front plate tool and a tommy bar hold the clutch plate stationary Place the bolt into th...

Page 819: ...he shaft key and lift the pulley assembly from the compressor Inspect the rotor assembly 8 for wear and replace the assembly as necessary Remove the field coil wire retaining clip Remove the snap ring...

Page 820: ...the coil 10 making sure that the wire is lo cated behind the clip on the outside of the body and that the snap ring 9 is located in the groove Position the rotor 8 on the housing hub and care fully sl...

Page 821: ...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 fron...

Page 822: ...must be discharged from the system and the compressor removed from the vehicle prior to replacing the shaft seal Z Remove the armature plate as detailed in the steps of clutch disassembly Z Remove th...

Page 823: ...y in clean re frigerant 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 t...

Page 824: ...64 SECTION 50 CAB HEATING AND AIR CONDITIONING Position the shims over the shaft and refit the shaft key Reinstall the plate as described in clutch reassem bly F28911 www maskinisten net Copyright...

Page 825: ...carefully remove the gasket 8 using a suitable scraper Gently pry the plate 7 free from the cylinder block and remove the gasket 6 Inspect the plate 7 for damage Coat the top of the valve plate with c...

Page 826: ...roughness is felt while rotating the hub the compressor should be disassembled 2 Using a 12 V battery test the current absorption of the field coil it must be between 3 6 and 4 2 A Very high current r...

Page 827: ...icles when servicing the air conditioning system This special equipment is available through recognized suppliers of air conditioning equipment P N DESCRIPTION USE 380000315 Recovery recharge portable...

Page 828: ...68 SECTION 50 CAB HEATING AND AIR CONDITIONING NOTES www maskinisten net Copyright...

Page 829: ...00 3 1 FRONT CONTROL PANELS 580SR 590SR 100 3 2 FRONT CONTROL PANELS 695SR 102 3 3 SIDE INSTRUMENT CLUSTER PANEL 580SR 104 3 4 SIDE INSTRUMENT CLUSTER PANEL 580SR 590SR 695SR 106 3 5 SIDE INSTRUMENT C...

Page 830: ...CTION 166 8 2 COMPONENT TESTING 167 8 3 GROUND POINTS 167 8 4 ALTERNATOR 170 8 5 TRANSMISSIONS 170 8 6 PARKING BRAKE SWITCH 174 8 7 CAB 175 8 8 4WD SWITCH 180 8 9 BRAKE PEDAL SWITCHES 180 8 10 BRAKE O...

Page 831: ...the damaged area and strip about 13 mm of insulation from the wires Do not cut away any wire strands Z Using a suitable solvent clean about 50 mm from each cover end Clean the grey cable cover and the...

Page 832: ...iscosity for the temperature conditions Starter motor inoperative Transmission shift lever in gear Loose or corroded connections Dead batteries Move gearshift lever to neutral Clean and tighten loose...

Page 833: ...level solenoid valve sensor clutch disconnect buttons F4C 10 A Backhoe attachment lock backhoe attachment travel lock rear work light F5A 15 A Inner front work lights F5B 10 A Low beams F5C 15 A Main...

Page 834: ...rn HA3 Optional buzzer K01 Starting relay K02 A C relay K13 Antitheft unit KC Fuse and relay control unit M1 Starter motor M10 Air conditioning compressor not connected R2 Engine water temperature sen...

Page 835: ...rk light optional 4 way connector X41 Blower motor optional 2 way connector NAME DESCRIPTION X44 Front right work light 4 way connector X45 Front right work light optional 4 way connector X46 Rear lef...

Page 836: ...way connector XC6 Control unit 13 way connector XD Engine stop diode 2 way connector XD1 Parking brake diode 2 way connector XST2 Side instrument cluster 36 way connector Y12 Proportional solenoid val...

Page 837: ...SECTION 55 ELECTRICAL SYSTEM 9 ENGINE LINE DIAGRAM www maskinisten net Copyright...

Page 838: ...R V1 3 5 X35 2 X35 1 EV2 1 2 EV10 X6 2 X6 1 31 1 5 31 3 1 N1 A R1 A R1 A R1 A R1 B R1 B R1 B R1 B R1 X28 2 X28 1 X23 2 X23 1 X10 11 X10 9 X10 24 X10 8 H N1 C1 XC3 1 X10 7 X10 20 H N1 H R1 H R1 X29 2...

Page 839: ...SECTION 55 ELECTRICAL SYSTEM 11 SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Page 840: ...12 SECTION 55 ELECTRICAL SYSTEM LIGHT LINE DIAGRAM www maskinisten net Copyright...

Page 841: ...SECTION 55 ELECTRICAL SYSTEM 13 REAR LIGHT LINE DIAGRAM www maskinisten net Copyright...

Page 842: ...14 SECTION 55 ELECTRICAL SYSTEM WORK LIGHT LINE DIAGRAM www maskinisten net Copyright...

Page 843: ...SECTION 55 ELECTRICAL SYSTEM 15 WINDSHIELD WIPER WASHER LINE DIAGRAM www maskinisten net Copyright...

Page 844: ...CTION 55 ELECTRICAL SYSTEM HEATER LINE F27499 G N1 S44 KC XC5 10 52 5 2 XC6 11 G N1 1 5 XC6 4 51 4 4 R N1 5 XC6 12 R N1 1 5 R N1 7 5 R N1 R N1 R N1 N1 3 2 1 X17 4 15 30 31 7 5 www maskinisten net Copy...

Page 845: ...17 COLD START DIAGRAM F27176 X82 10 L N1 V B1 X2 5 N1 B N1 X2 3 X2 4 S1 M1 X2 1 X2 2 TO ENGINE LINE X2 6 X82 8 X82 6 X82 7 X82 4 X82 3 X82 5 CONTROLLER X82 1 N1 X83 2 G1 X83 1 RELAY R1 GRID HEATER ww...

Page 846: ...6 230 240 OHMS REF Descending 102 OHMS 1 2 Tank 3 REF 98 108 OHMS Descending 33 OHMS Full 4 2 33 42 OHMS Ascending Transmission temperature 900 OHMS Point B 0 6 N A Descending 114 OHMS 106 C Red gree...

Page 847: ...Not used 15 Engine pre heat High side switch input LP12 16 Not used 17 Direction High side switch input LP14 18 Not used 19 Tachometer signal Alternator w input 20 Fuel level sender Speed sensor input...

Page 848: ...solenoid valve sensor clutch disconnect buttons F4C 10 A Backhoe attachment lock backhoe attachment travel lock rear work light F5A 15 A Inner front work lights F5B 10 A Low beams F5C 15 A Main beams...

Page 849: ...nt intake illumination H18 Cab light H19 Inner front left work light optional H20 Inner front right work light optional H21 Inner rear left work light optional H22 Inner rear right work light optional...

Page 850: ...Clutch disconnect button 2 way connector NAME DESCRIPTION X24 Backhoe attachment travel lock solenoid valve 2 way connector X25 Backhoe attachment lock solenoid valve 2 way connector X26 Bucket sensor...

Page 851: ...way connector X81 Beacon lamp 2 way connector X82 Control unit 10 way connector X83 Relay 2 way connector X87 General line left side instrument cluster line 13 way connector X88 General line right sid...

Page 852: ...24 SECTION 55 ELECTRICAL SYSTEM ENGINE LINE DIAGRAM www maskinisten net Copyright...

Page 853: ...R V1 3 5 X35 2 X35 1 EV2 1 2 EV10 X6 2 X6 1 31 1 5 31 3 1 N1 A R1 A R1 A R1 A R1 B R1 B R1 B R1 B R1 X28 2 X28 1 X23 2 X23 1 X10 11 X10 9 X10 24 X10 8 H N1 C1 XC3 1 X10 7 X10 20 H N1 H R1 H R1 X29 2...

Page 854: ...26 SECTION 55 ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Page 855: ...R 7 49 4 30b 2 49a 5 L 6 51 8 3 V N1 5 7 1 A1 7 1 L N1 7 1 L1 7 1 50 7 5 15 F2A 15A F5C 15A F6B 7 5A 15 H3 56b 56a R 58 31 11 5 1 10 5 1 A1 5 1 L1 5 1 X22 3 H2 56b 56a L 58 31 S31 XC3 10 XC4 13 F7A 10...

Page 856: ...48 4 3 2 1 XC1 2 XC1 8 B R1 R1 R N1 2 5 R N1 R N1 XC5 17 XC1 7 11 4 2 G N1 XC5 8 L1 4 5 L1 L1 XC5 7 XC4 17 A1 4 5 A1 A1 XC4 19 XC5 9 G1 10 4 2 XC5 6 G1 A1 XC3 20 XC3 12 R N1 XC3 21 R N1 G1 A1 7 10 8 R...

Page 857: ...7 1 C N1 7 1 31 7 1 31 5 5 X46 4 3 2 1 V N1 X40 4 3 2 1 N1 H N1 X38 4 3 2 1 N1 H N1 X47 4 3 2 1 V1 X45 4 3 2 1 N1 H1 X44 4 3 2 1 X50 4 3 2 1 H1 N1 X51 4 3 2 1 XC5 11 XC5 13 XC5 12 XC5 14 H1 V N1 H N1...

Page 858: ...1 4 5 L N1 4 5 A1 4 5 11 10 9 L N1 A1 L1 V N1 5 4 5 G R1 2 2 5 4 V N1 5 G R1 A V1 5 XC5 16 XC2 1 A V1 5 A G1 5 XC4 1 A G1 5 C N1 XC3 7 A B1 6 XC4 14 A B1 XC5 3 X49 1 A B1 R N1 4 XC5 4 R N1 A R1 8 XC4...

Page 859: ...8 ON M N1 B R1 G1 H17 N1 X55 N1 G1 5 5 R N1 S46 X55 l N1 N4 2 X111 1 R4 S35 S34 X110 1 30 XC6 4 Z2 5 R N1 5 XC6 12 XC5 10 F2B 15A 15 F7B 10A 30 2 2 BS1 BS2 N0 5 R0 5 R0 5 N0 5 R N1 6 5 4 7 3 1 2 X54 8...

Page 860: ...TEM COLD START DIAGRAM F27176 X82 10 L N1 V B1 X2 5 N1 B N1 X2 3 X2 4 S1 M1 X2 1 X2 2 TO ENGINE LINE X2 6 X82 8 X82 6 X82 7 X82 4 X82 3 X82 5 CONTROLLER X82 1 N1 X83 2 G1 X83 1 RELAY R1 GRID HEATER ww...

Page 861: ...6 230 240 OHMS REF Descending 102 OHMS 1 2 Tank 3 REF 98 108 OHMS Descending 33 OHMS Full 4 2 33 42 OHMS Ascending Transmission temperature 900 OHMS Point B 0 6 N A Descending 114 OHMS 106 C Red gree...

Page 862: ...Not used 15 Engine pre heat High side switch input LP12 16 Not used 17 Direction High side switch input LP14 18 Not used 19 Tachometer signal Alternator w input 20 Fuel level sender Speed sensor input...

Page 863: ...86 87a 87 85 30 2 1 10 11 S Evaporator box 1 3rd speed relay 2 Fuse 25 A 3 Ventilated electrical motor 4 1 and 2 speed resistor 5 Electrical cock X111 9 way connector X110 2 way power connector S45 11...

Page 864: ...er supply differential lock switch F4B 10 A Rear hammer button bucket level solenoid valve sensor F4C 10 A Backhoe attachment lock backhoe attachment travel lock F5A 15 A Inner front work lights F5B 1...

Page 865: ...light optional H20 Inner front right work light optional H21 Inner rear left work light optional H22 Inner rear right work light optional HA1 Reverse buzzer HA2 Horn HA3 Optional buzzer K01 Starting r...

Page 866: ...r X23 EGS 9 way connector X24 Backhoe attachment travel lock solenoid valve 2 way connector NAME DESCRIPTION X25 Backhoe attachment lock solenoid valve 2 way connector X26 Bucket sensor 3 way connecto...

Page 867: ...nnector X84 Gearshift extension 13 way connector X85 Gearshift 12 way connector X87 General line side instrument cluster line 13 way connector X88 General line side instrument cluster line 9 way conne...

Page 868: ...40 SECTION 55 ELECTRICAL SYSTEM ENGINE LINE DIAGRAM www maskinisten net Copyright...

Page 869: ...V0 5 E J H F L B0 5 X83 V X84 13 B V0 5 B0 5 12 A 11 R M0 5 10 P H0 5 S 9 V0 5 8 L S0 5 N 7 N0 5 6 T G0 5 D L0 5 B R0 5 C B G0 5 5 4 M U B M0 5 3 Z0 5 2 G H B0 5 K 1 B S0 5 S50 5 A B1 4 1 A B1 6 7 M N...

Page 870: ...42 SECTION 55 ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Page 871: ...B1 2 3 A B1 KC XC5 2 1 0 S42 15 1 30 3 R 7 49 4 30b 2 49a 5 L 6 51 8 3 V N1 5 7 1 50 7 5 15 F2A 15A F5C 15A F6B 7 5A 15 XC1 2 XC1 8 H3 56b 56a R 58 31 11 5 1 10 5 1 A1 5 1 L1 5 1 H2 56b 56a L 58 31 S...

Page 872: ...N1 X37 4 3 2 1 G N1 X48 4 3 2 1 R1 R N1 2 5 R N1 XC5 17 XC1 7 11 4 2 XC5 8 L1 4 5 L1 XC5 7 XC4 17 A1 4 5 A1 XC4 19 XC5 9 10 4 2 XC5 6 G1 A1 XC3 20 XC3 12 R N1 XC3 21 R N1 G1 A1 7 10 8 R N1 G1 A1 G N1...

Page 873: ...N1 7 1 C N1 7 1 31 7 1 N1 31 5 5 X46 4 3 2 1 V N1 X40 4 3 2 1 N1 H N1 X38 4 3 2 1 N1 H N1 X47 4 3 2 1 V1 X45 4 3 2 1 N1 H1 X44 4 3 2 1 X50 4 3 2 1 H1 N1 X51 4 3 2 1 XC5 11 XC5 13 XC5 12 XC5 14 H1 V N...

Page 874: ...A G1 5 X43 4 3 2 1 L1 4 5 L N1 4 5 A1 4 5 11 10 9 L N1 A1 L1 V N1 5 4 5 G R1 2 1 5 4 V N1 5 G R1 A V1 5 XC5 16 XC2 1 A V1 5 A G1 5 XC4 1 A G1 5 C N1 XC3 7 A B1 6 XC4 14 A B1 XC5 3 X49 1 A B1 R N1 4 XC...

Page 875: ...B R1 G1 H17 N1 X55 N1 G1 5 5 R N1 S46 X55 l N1 N4 2 X111 1 R4 S35 S34 X110 1 30 XC6 4 Z2 5 R N1 5 XC6 12 XC5 10 F2B 15A 15 F7B 10A 30 2 2 BS1 BS2 N0 5 R0 5 R0 5 N0 5 R N1 6 5 4 7 3 1 2 X54 8 X14 4 XC...

Page 876: ...TEM COLD START DIAGRAM F27176 X82 10 L N1 V B1 X2 5 N1 B N1 X2 3 X2 4 S1 M1 X2 1 X2 2 TO ENGINE LINE X2 6 X82 8 X82 6 X82 7 X82 4 X82 3 X82 5 CONTROLLER X82 1 N1 X83 2 G1 X83 1 RELAY R1 GRID HEATER ww...

Page 877: ...6 230 240 OHMS REF Descending 102 OHMS 1 2 Tank 3 REF 98 108 OHMS Descending 33 OHMS Full 4 2 33 42 OHMS Ascending Transmission temperature 900 OHMS Point B 0 6 N A Descending 114 OHMS 106 C Red gree...

Page 878: ...Not used 15 Engine pre heat High side switch input LP12 16 Not used 17 Direction High side switch input LP14 18 Not used 19 Tachometer signal Alternator w input 20 Fuel level sender Speed sensor input...

Page 879: ...A 3 Ventilated electrical motor 4 1 and 2 speed resistor 5 Electrical cock X111 9 way connector X110 2 way power connector S45 11 way connector 9 Potentiometer 10 Speed switch 11 Temperature switch 1...

Page 880: ...RH STAB XR A XR B XR C JOYSTICK LH STAB XL A XL B XL C RETRACT PLUG 8 EXTEND YP8 1 YP7 2 YP8 2 X14 2 RIGHT JOYSTICK X12 2 31 P7 HORN JUMPER P8 L R 1 2 CONNECTION L R A N1 X20 9 L G1 X20 7 X20 8 A R1...

Page 881: ...power 2 way connector X20 Control unit 23 way connector X23 Safety switch 2 way connector X24 Left stabilizer control lever 6 way connector X27 Horn jumper connection 2 way connector X72 Pilot control...

Page 882: ...hift lever F4B 10 A Rear hammer button bucket level solenoid valve sensor clutch disconnect buttons F4C 10 A Backhoe attachment lock backhoe attachment travel lock F5A 15 A Inner front work lights F5B...

Page 883: ...fuse F4 Third speed blower fuse F5 Water in fuel fuse F31 Fuse for anti theft device diagnostic socket menu scroll switch display enter switch side instrument cluster FG4 Fuse A C G1 Battery G67 Alte...

Page 884: ...Anti theft device 11 way connector X15 1 Start connector X15 6 Start connector X17 Optional seat 4 way connector X21 Diagnostics 10 way connector X22 5 way connector X23 2 way connector X24 Accelerato...

Page 885: ...203 Backhoe attachment lock solenoid valve 2 way connector X204 Horn switch 2 way connector X206 Bucket level 2 way connector X207 Speed control solenoid valve optional 2 way connector X208 Loader att...

Page 886: ...58 SECTION 55 ELECTRICAL SYSTEM ENGINE LINE DIAGRAM www maskinisten net Copyright...

Page 887: ...SECTION 55 ELECTRICAL SYSTEM 59 SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Page 888: ...60 SECTION 55 ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Page 889: ...SECTION 55 ELECTRICAL SYSTEM 61 LIGHT LINE DIAGRAM www maskinisten net Copyright...

Page 890: ...62 SECTION 55 ELECTRICAL SYSTEM REAR LIGHT LINE DIAGRAM www maskinisten net Copyright...

Page 891: ...SECTION 55 ELECTRICAL SYSTEM 63 WORK LIGHT LINE DIAGRAM www maskinisten net Copyright...

Page 892: ...64 SECTION 55 ELECTRICAL SYSTEM WINDSHIELD WASHER WIPER LINE DIAGRAM www maskinisten net Copyright...

Page 893: ...SECTION 55 ELECTRICAL SYSTEM 65 HEATER LINE www maskinisten net Copyright...

Page 894: ...A 3 Ventilated electrical motor 4 1 and 2 speed resistor 5 Electrical cock X111 9 way connector X110 2 way power connector S45 11 way connector 9 Potentiometer 10 Speed switch 11 Temperature switch 1...

Page 895: ...6 230 240 OHMS REF Descending 102 OHMS 1 2 Tank 3 REF 98 108 OHMS Descending 33 OHMS Full 4 2 33 42 OHMS Ascending Transmission temperature 900 OHMS Point B 0 6 N A Descending 114 OHMS 106 C Red gree...

Page 896: ...Not used 25 Transmission oil pressure Digital input 26 Not used CN2 PIN FUNCTION NOTE 1 Keep alive power Need to fuse at 1 ampere without disconnect 2 Not used 3 Can bus input Twisted pair with 120 O...

Page 897: ...h transmission disconnect button EGS power supply F4B 10 A Rear hammer button bucket level solenoid valve sensor F4C 10 A Backhoe attachment lock backhoe attachment travel lock F5A 15 A Inner front wo...

Page 898: ...er fuse F5 Water in fuel fuse F31 Fuse for anti theft device diagnostic socket menu scroll switch display enter switch side instrument cluster FG4 Fuse A C G1 Battery G67 Alternator H7 Reverse buzzer...

Page 899: ...tor X45 Air conditioning 11 way connector X46 Rear left light 4 way connector X47 Rear left light 4 way connector X48 4 way connector NAME DESCRIPTION X49 6 way connector X50 Front right lights 4 way...

Page 900: ...e and relay control unit line interface general line 17 way connector XC6 Fuse and relay control unit line interface general line 13 way connector XST1 Side instrument cluster 20 way connector XST2 Fr...

Page 901: ...SECTION 55 ELECTRICAL SYSTEM 73 ENGINE LINE DIAGRAM www maskinisten net Copyright...

Page 902: ...74 SECTION 55 ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Page 903: ...SECTION 55 ELECTRICAL SYSTEM 75 SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Page 904: ...76 SECTION 55 ELECTRICAL SYSTEM LIGHT LINE DIAGRAM www maskinisten net Copyright...

Page 905: ...SECTION 55 ELECTRICAL SYSTEM 77 REAR LIGHT LINE DIAGRAM www maskinisten net Copyright...

Page 906: ...78 SECTION 55 ELECTRICAL SYSTEM WORK LIGHT LINE DIAGRAM www maskinisten net Copyright...

Page 907: ...SECTION 55 ELECTRICAL SYSTEM 79 WINDSHIELD WASHER WIPER LINE DIAGRAM www maskinisten net Copyright...

Page 908: ...80 SECTION 55 ELECTRICAL SYSTEM HEATER LINE www maskinisten net Copyright...

Page 909: ...A 3 Ventilated electrical motor 4 1 and 2 speed resistor 5 Electrical cock X111 9 way connector X110 2 way power connector S45 11 way connector 9 Potentiometer 10 Speed switch 11 Temperature switch 1...

Page 910: ...193 OHMS ON 5 OHMS 185 OHMS OFF 5 OHMS TACHOMETER Can message 0 3000 RPM 50 RPM COOLANT Can message Minimum reading 65 C 3 C Can message Left edge of red band 106 C 2 C Can message Maximum reading 112...

Page 911: ...Not used 25 Transmission oil pressure Digital input 26 Not used CN2 PIN FUNCTION NOTE 1 Keep alive power Need to fuse at 1 ampere without disconnect 2 Not used 3 Can bus input Twisted pair with 120 O...

Page 912: ...ride control dou ble delivery F4A 7 5 A 4WD switch transmission disconnect button EGS power supply F4B 10 A Rear hammer button bucket level sole noid valve sensor F4C 10 A Backhoe attachment lock bac...

Page 913: ...alarm E133 Front right light F1 Main fuse F2 Power supply fuse F4 Third speed blower fuse F5 Water in fuel fuse F31 Fuse for anti theft device diagnostic socket menu scroll switch display enter switc...

Page 914: ...l 2 way connector X35 Hand hammer button 2 way connector NAME DESCRIPTION X36 Rear hammer button 2 way connector X37 Rear right light 4 way connector X38 Rear right light 4 way connector X39 Rear wind...

Page 915: ...way connector XC5 Fuse and relay control unit line interface general line 17 way connector XC6 Fuse and relay control unit line interface general line 13 way connector XST1 Side instrument cluster 20...

Page 916: ...88 SECTION 55 ELECTRICAL SYSTEM ENGINE LINE DIAGRAM www maskinisten net Copyright...

Page 917: ...SECTION 55 ELECTRICAL SYSTEM 89 SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Page 918: ...90 SECTION 55 ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Page 919: ...SECTION 55 ELECTRICAL SYSTEM 91 LIGHT LINE DIAGRAM www maskinisten net Copyright...

Page 920: ...92 SECTION 55 ELECTRICAL SYSTEM REAR LIGHT LINE DIAGRAM www maskinisten net Copyright...

Page 921: ...SECTION 55 ELECTRICAL SYSTEM 93 WORK LIGHT LINE DIAGRAM www maskinisten net Copyright...

Page 922: ...94 SECTION 55 ELECTRICAL SYSTEM WINDSHIELD WASHER WIPER LINE DIAGRAM www maskinisten net Copyright...

Page 923: ...SECTION 55 ELECTRICAL SYSTEM 95 HEATER LINE www maskinisten net Copyright...

Page 924: ...96 SECTION 55 ELECTRICAL SYSTEM STEERING LINE DIAGRAM www maskinisten net Copyright...

Page 925: ...A 3 Ventilated electrical motor 4 1 and 2 speed resistor 5 Electrical cock X111 9 way connector X110 2 way power connector S45 11 way connector 9 Potentiometer 10 Speed switch 11 Temperature switch 1...

Page 926: ...193 OHMS ON 5 OHMS 185 OHMS OFF 5 OHMS TACHOMETER Can message 0 3000 RPM 50 RPM COOLANT Can message Minimum reading 65 C 3 C Can message Left edge of red band 106 C 2 C Can message Maximum reading 112...

Page 927: ...Not used 25 Transmission oil pressure Digital input 26 Not used CN2 PIN FUNCTION NOTE 1 Keep alive power Need to fuse at 1 ampere without disconnect 2 Not used 3 Can bus input Twisted pair with 120 O...

Page 928: ...lamp on NOTE when the 4WD switch is in OFF position and the two brake pedals are pressed at the same time the 4 wheel drive is engaged automatically at speeds higher than 3 km h to ensure braking on t...

Page 929: ...nual 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...

Page 930: ...wo brake pedals are pressed at the same time the 4 wheel drive is engaged automatically at speeds higher than 3 km h to ensure braking on the 4 wheels it disengages when the brake pedals are released...

Page 931: ...g the load er attachment 8 MANUAL MODE SELECTION SWITCH Powershift transmission In situations where manual gearshifting up or downshift is required the automatic gearshift of the powershift transmissi...

Page 932: ...bout to start working with the backhoe attach ment in conditions which could cause the ma chine to roll over he she must activate the roll over protection device by pressing the switch ON position and...

Page 933: ...n this switch is pressed the windshield wip er is activated and will continue operating until the switch is returned to the OFF position 8 REAR WINDSHIELD WASHER SWITCH The windshield washer will oper...

Page 934: ...e When the operator is about to start working with the backhoe attach ment in conditions which could cause the ma chine to roll over he she must activate the roll over protection device by pressing th...

Page 935: ...nfirm the menu options shown on the dis play 10 REAR WINDSHIELD WIPER AND WASHER SWITCH When this switch is pressed the windshield wip er is activated and will continue operating until the switch is r...

Page 936: ...E WARNING LAMP This warning lamp turns on and the audible warning device sounds when the engine oil pressure is too low If the lamp turns on while the machine is work ing move the machine to a safe pl...

Page 937: ...fuel tank 15 HOURMETER The hourmeter shows the number of hours and tenths of hours the engine has been functioning It also makes it possible to determine when servicing operations are due 16 TACHOMETE...

Page 938: ...BRAKE LIQUID LEVEL WARNING LAMP This lamp turns on and the audible warning de vice sounds when the brake liquid is at minimum level 6 FOUR WHEEL STEER 4WS STEER INDI CATOR LAMP This lamp turns on when...

Page 939: ...nd 19 set to position 18 FUEL LEVEL GAUGE This gauge shows the quantity of fuel in the fuel tank 19 BATTERY CHARGE GAUGE This indicator shows the state of charge of the battery At normal charge the ne...

Page 940: ...supply 2 30 Permanent 12 V power supply Connected to the wire from the battery positive 3 31 Negative power supply Connected to the vehicle negative at two independent points 5 6 Immobilization relay...

Page 941: ...ion of the switch is used to select displays The 90 arrow icon or bottom portion of the switch is used to enter selected choices Features adjustable during setup backlighting dimming and contrast cont...

Page 942: ...ture too high Engine coolant level too low Engine coolant too high Engine oil pressure too low Brake fluid level too low Parking brake engaged Put the shuttle lever into neutral position HEAVY 1000 LI...

Page 943: ...cond scroll unless the up down button is pressed Total no of pages CODE OCCUR RENCE Select Deselect Low and high idle speed Increase O Decrease P Increase O Decrease P O Press Enter to make the value...

Page 944: ...h off after 2 seconds 10 mA Current draw 100 mA Voltage XX X Trans oil temp XX 116 124 range Step 6 Wait 2 seconds Step 7 Sweep all 5 gauges to maximum angle Makes sure that needles can move freely an...

Page 945: ...ge 3 6 Occurrence counter will be incremented on transition from inactive to active status Status has to be stored in EEPROM and checked at key on Only the hour count of the last occurrence will be st...

Page 946: ...ntensity of luminance between closed points is 15 Note that the matrix backlight ing may go to 0 by customer selection The lamps and the audible alarm will warn the customer of an alarm condition occu...

Page 947: ...ease or decrease the value of one unit 6 min Continuous switch pressure will increase or decrease the value continuously 1 every 300 milliseconds when the value reaches a multiple of 10 the increment...

Page 948: ...ey OFF all indicators must be set to the parking position The parking position is hard to ob tain with the internal stops of the stepper motor With the key ON follow the procedure below Needle collisi...

Page 949: ...riate warning lamp and lamp will be illuminated During cranking the needle movement shall be fro zen in order to inhibit any spurious movement of it VOLTMETER GAUGE The voltmeter will indicate the vol...

Page 950: ...s temperature The same range of temperature is used for power shift and powershuttle transmissions The gauge will move 9 angular degrees at key on in the clock wise position to replicate the current p...

Page 951: ...en sor that will provide specific a resistance to correlate to a specific fuel tank level Z X empty The centerline CL of the pointer will be 0 2 angular degrees of the centerline of this emp ty mark Z...

Page 952: ...he buzzer the display will show an icon symbol that identi fies the occurring problem 2 There are conditions in which the diagnostic de tects one of its sensors out of order in this case it will gener...

Page 953: ...itical A failure is present but the operator can continue his work the purpose is to warn him regarding the presence of the fault This will be a 1 second beep every 30 seconds Critical A serious fault...

Page 954: ...ized 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 NOTE the symbols will show up as foll...

Page 955: ...1 Red Malfunction Continuous 25 seconds without message 1053 ECU Timeout of message 1 Red Malfunction Continuous 5 seconds without message 1054 VCM Timeout of message engine temperature 1 Red Malfunct...

Page 956: ...Continuous 3051 ECU Batteryvoltage too high 2 Red Battery charge voltage too high Continuous Supply source above 16 V for 5 seconds 1014 VCM Supply battery voltage above 16 V 2 Red Battery charge volt...

Page 957: ...of range One second alarm every 30 seconds Accelerator under 0 5 V for 5 seconds 1030 VCM Foot accelerator sensor shorted low to Vbat 2 Amber Foot accelerator 5 V supply One second alarm every 30 seco...

Page 958: ...nal out of range One second alarm every 30 seconds Accelerator under 0 5 V for 5 seconds 1039 VCM Hand accelerator sensor shorted low to ground 2 Amber Hand accelerator 5 V supply One second alarm eve...

Page 959: ...perature signal source high 3 Amber Transmissi on oil above 105 C One second alarm every 30 seconds Coolant above105 C for 5 seconds 1020 VCM Transmission over operating temperature 3 Amber Fuel tempe...

Page 960: ...seconds 1044 VCM Fuel sender shorted low park gauge 4 Amber Fuel level sensor One second alarm every 30 seconds Input is switched battery for 5 seconds 1045 VCM Fuel sender open circuit park gauge 4 A...

Page 961: ...emperature sender out of range 4 Amber General display message One second alarm DTC s 3000 3366 VCM Only display with display request 4 Amber Low fuel warning One second alarm VCM Low fuel must stay o...

Page 962: ...hen the ring gear and the drive pinion are engaged the mobile core of the solenoid closes a series of contacts ena bling the battery to power the field coils directly and provide the entire power to t...

Page 963: ...Is there a voltage of 12 V at terminal 86 white black after the reverse travel lever is oper Are the cable wires of the reverse travel lever properly con nected Does the reverse travel lever switch o...

Page 964: ...positive terminal of the battery and the negative cable to the input terminal of the solenoid 3 Reconnect the ground cable negative of the battery to the negative terminal of the battery 4 Connect th...

Page 965: ...it is still exces sive replace the cable Starter motor connections to ground 1 Connect the positive cable of the voltmeter 1 to the body of the starter motor 2 2 Connect the negative cable of the volt...

Page 966: ...aximum consumption without load at 11 V and 3000 rpm minimum 200 A maximum Maximum consumption with a torque of 19 6 Nm at 8 V and 1130 rpm minimum 600 A maximum Maximum consumption when shimming at 3...

Page 967: ...SECTION 55 ELECTRICAL SYSTEM 139 www maskinisten net Copyright...

Page 968: ...rain 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 W...

Page 969: ...le 4 of the battery to the mounting flange of the starter motor Z Connect a short cable 6 between the solenoid battery wire and the terminals of the solenoid switch Z Connect the positive cable of the...

Page 970: ...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 nec...

Page 971: ...the magnetic switch Repair or replace the motor assembly The starter motor runs too slowly Poor magnetic switch contact Motor assembly malfunction e g layer short brush wear Replace the magnetic switc...

Page 972: ...arts and the partially magnetized rotor rotates inside the stator a three phase alter nating current is generated terminal B A constant portion of this current is transformed into a direct cur rent by...

Page 973: ...ICAL SYSTEM 145 DIAGRAM OF THE CHARGING CIRCUIT 1 Alternator 2 Output winding of the rotor 3 Rectifier 4 Regulator 5 Starter motor 6 Battery 7 Key switch 8 Charge indicator 9 Speedometer www maskinist...

Page 974: ...r 6 Rear protective 7 Insulation ring 8 Insulation ring 9 Screw 10 Screw 11 Nut 12 Nut 13 Rotor 14 Pulley 15 Pulley nut 16 Sealing ring 17 Sealing ring 18 Washer 19 Screw 20 Electrical terminal 21 Scr...

Page 975: ...e cable from the battery 2 Disconnect the battery cable 1 from terminal B 2 3 Disconnect the connector 3 Removing the alternator 1 Free the tension roller 1 using a suitable wrench then remove the bel...

Page 976: ...ening of con nections Checking the battery Check each cell of the battery with a hydrometer The battery must be charged at least 70 and be in good condition Checking the drive belt Check that the belt...

Page 977: ...TIONS OF THE ALTERNATOR CABLES Z Disconnect the battery Z Disconnect the terminals B 2 and L 3 from the alternator Z Reconnect the battery and turn the ignition key without starting the motor Connect...

Page 978: ...2000 rpm Observe the values shown on the ammeter and the voltmeter The voltage shown on the voltmeter should at first be too high and then should stabilize between 14 2 14 8 V when the value on the a...

Page 979: ...sufficient and the millivoltmeter in dicates a value that is less than 400 millivolts an al ternator component is defective Carry out the operations described in the Checking the alternator component...

Page 980: ...B negative side towards the cable Z Connect a voltmeter 4 between terminal B of the alternator and the ground Z Reconnect the battery start the motor and in crease its speed to 2000 rpm Z Gradually r...

Page 981: ...evices Z 12 V battery Z Multimeter Z 2 2 W test lamp CHECKING THE REGULATOR AND THE FIELD CIRCUIT OF THE REGULATOR Z Disconnect all cables from the alternator Z Connect a 12 V battery and a 2 2 W test...

Page 982: ...eries on the excitation diode module Place the negative wire on terminal L 1 and the other wire on the connection of each excitation diode 3 Z Note down the value of the resistance indicated by the mu...

Page 983: ...t the slip rings are clean and smooth If necessary clean them with a cloth soaked in gaso line If the slip rings are burnt scrape them with very fine sandpaper do not use emery cloth and wipe them NOT...

Page 984: ...INSULATION OF THE FIELD WINDING Z Using an ohmmeter 3 measure the resistance between each slip ring 2 and the rotor terminals 1 The resistance should always be infinite If a re sistance is not infini...

Page 985: ...t Replace the part Recharge insufficient Slackened fan belt Voltage regulator faulty Excessive wear of rotor rings or brushes Short circuited diodes Stator windings or rotor winding short circuited Su...

Page 986: ...oaches full charge This can be caused by a faulty charging sys tem or boost recovery charging equipment The battery has four major functions Z To provide a source of current for starting lighting and...

Page 987: ...ative cable first Z When reconnecting the battery cables always con nect the negative cable last Z Never short circuit the battery terminals with metal objects Z Do not weld grind or smoke near a batt...

Page 988: ...old bat tery Z Install the new battery Z Install the brackets 5 the clamping bar 4 and the washers and nuts 3 Z Clean the cables and the connecting terminals and coat them with grease Z Connect the ca...

Page 989: ...be exceeded by con stant and excessive overloading and that charging requirements are maintained MAINTENANCE S WARNING Battery electrolyte causes severe burns The bat tery contains sulphuric acid Avo...

Page 990: ...raises the temperature of the electrolyte and unless the charger is equipped with an auto matic time or temperature device the electrolyte temperature could exceed 50 C which may cause violent battery...

Page 991: ...erwise accurate hydrometer readings will not be ob tained If the battery has been charged under static condi tions denser electrolyte will accumulate at the bot tom of the cells The battery should be...

Page 992: ...175 45 minutes 1 176 to 1 200 30 minutes 1 201 to 1 225 15 minutes Slow charge only NOTE when battery problems are experienced the fan belt tension and the complete charging system should be checked C...

Page 993: ...e terminal of the machine s battery Z Connect the negative jumper cable to one of the fastening screws 1 of tank Z Start the engine Z First disconnect the negative jumper cable then disconnect the pos...

Page 994: ...are colour coded for identification Each harness can be removed and replaced but cer tain precautions must be observed Z Disconnect or isolate the battery negative terminal first prior to disconnecti...

Page 995: ...NOTE always ensure the ground points are clean and functional A poor ground will cause the electrics to fail Ground point A Starter motor engine harness Ground point A is also linked to ground point B...

Page 996: ...o a back up ground point for Location E Ground point E Top right hand B pillar roof harness Ground point F Operator seat light F28379 F5 B F5 A F8 C F8 B F8 A F7 C F7 B F7 A F6 C F6 B F6 A K8 K9 K7 K6...

Page 997: ...ed to ON the audible alarm sounds until the en gine is started or the key is returned to the initial po sition Starter switch key 1 Not used 2 Off 3 Ignition ON 4 Cranking CONTACTS MAXIMUM CURRENT 12...

Page 998: ...POWERSHUTTLE DISCONNECT X23 X28 Energizes the transmission dump solenoid at 12 V Test procedure Continuity should be found between pin 1 and pin 2 when switch is operated POWERSHIFT EGS CONNECTOR The...

Page 999: ...ich sends signals back to the EGS Test Procedure Test between pin indicated in the left hand column and either pin H or M as detailed in the table below A Speed sensor plus output 24 B Forward Lo Hi s...

Page 1000: ...serve the second volt age V2 Test procedure The special tool connects to pin A speed sensor plus output and pin J speed sensor temperature sensor ground Description A Speed sensor B FWD request C Disc...

Page 1001: ...nuity should be found between pin 1 and pin 2 when switch is operated OIL PRESSURE SWITCH POWERSHIFT Energized at 12 V if the transmission pressure is to low the warning lamp will flash Test procedure...

Page 1002: ...d 8 7 PARKING BRAKE SWITCH When the parking brake is engaged the switch is deactivated and the warning lamp turns on An audible alarm sounds if the parking brake is op erated with the gearshift lever...

Page 1003: ...TER CONNECTOR AMPERE 070 12 WAY POWERSHUTTLE Pin functions and test procedure Listed below are the pin numbers warning lights and gauges 1 Starter switch key 12 V 2 Ground check continuity 3 Tachomete...

Page 1004: ...ON 5 OHMS 200 OHMS OFF 5 OHMS TACHOMETER Can message 0 3000 RPM 50 RPM COOLANT TEMPERATURE Can message Minimum reading 65 C 3 C Can message Left edge of red band 106 C 2 C Can message Maximum reading...

Page 1005: ...ressure Digital input 11 Display input switch Digital input 12 Enter input switch Digital input 13 Up input switch Digital input 14 Down input switch Digital input 15 Cranking Digital input 16 Air fil...

Page 1006: ...HM relay 300 mA 8 Not used 9 Not used 10 Not used 11 Not used 12 Not used 13 Fuel level gauge Variable resistance 14 Transmission temperature Thermistor 15 Not used 16 Foot accelerator 0 5 4 5 V 17 Ac...

Page 1007: ...ti function switch on 6 12 V and instrument backlighting 7 Not used 8 4WS Green warning light four wheel input With Ignition ON and 4WS selected 0 5 V should be indicated With 2WS or crab steer select...

Page 1008: ...llow 12 V to relay Voltage Left switch White red wire 12 V continuous with ignition ON Red wire 12 V pedal depressed 0 V pedal released Right switch Red wire 12 V pedal depressed 0 V pedal released Re...

Page 1009: ...hould be seen when the level is low or the test button pushed Voltage With the Ignition ON there should be 12 V at the Red Black terminal 8 12 FRONT WORK LAMP SWITCH 1 REAR WORK LAMP SWITCH 2 MAIN LIG...

Page 1010: ...nal at all times in conjunction with the haz ard switch Continuity Pin No Switch OFF Switch ON 1 to pin 4 3 to pins 5 6 7 4 to pin 1 5 to pins 2 3 6 7 6 to pins 2 3 5 7 7 to pins 2 3 5 Pin No Hazard I...

Page 1011: ...in No All switches OFF Wind shield washer Indicator Beam Wiper seal Left Right Low High On 1 2 pin 7 3 pin 4 4 pin 5 pin 3 5 pin 4 6 pin 8 7 pin 2 pin 8 8 pin 6 pin 7 9 pin 11 10 pin 11 11 pin 9 pin 1...

Page 1012: ...WITCH At key start 12 V should be found at the switch and is directed to the steering sensors when a switch se lection is made Test procedure With ignition ON Pin 2WS 4WS CRAB A 12 V 12 V 12 V B 12 V...

Page 1013: ...guration 3 Front alignment sensor input 12 4 Crab steering control 12 5 Buzzer output 6 Rod iron steering control 12 7 Control unit supply 12 8 Ground 9 Speed sensor input 10 Rear alignment sensor inp...

Page 1014: ...ilure has been de energized or the correct operation has been reset Buzzer operation Buzzer operation depends on setting of pin 2 of the 12 way connector Z Pin 2 not connected North America only If 12...

Page 1015: ...on is made X98 8 20 4WS FRONT AXLE STEERING SENSOR At key start 12 V should be found at the switch and is directed to the steering sensor when a switch se lection is made X97 Pin 2WS 4WS CRAB A 12 V 1...

Page 1016: ...ront of loader backhoe Solenoid 2WS 4WS CRAB EVA2 0 V 0 V 12 V EVA3 0 V 12 V 12 V EVB2 12 V 12 V 0 V EVB3 12 V 0 V 0 V Pin No Solenoid Resistance 1 0 V 5 0 Pin No Solenoid Resistance 1 0 V 5 0 F28447...

Page 1017: ...V and when operated energizes the differential solenoid valve Test procedure Switch Off Continuity should not be found between any pins Switch On Continuity shoud be found between pins 1 and 5 Pin No...

Page 1018: ...machine is raised using the loader bucket do not operate the glide switch ensure it is switched OFF Test procedure Switch Off Continuity should not be found between any pins Switch On Continuity shou...

Page 1019: ...loader attachment lock when actuated is de signed to prevent movement of the loader attach ment during road travel Continuity should be found between pin 1 and 3 Pin No Solenoid Resistance 1 0 V 5 0 F...

Page 1020: ...he moving speed of the loader attachment Test procedure Switch Off Continuity should not be found between any pins Switch On Continuity shoud be found between pins 1 and 5 Pin No Solenoid Resistance 1...

Page 1021: ...sengage engage the backhoe attachment travel lock cylin ders Test procedure Switch Off Continuity should not be found between any pins Switch On Continuity shoud be found between pins 1 and 5 Pin No S...

Page 1022: ...for the operation of the backhoe attachment lock Test procedure Switch Off X25 Continuity shoud be found between pins 1 and 5 Switch On Continuity shoud be found between pins 5 and 7 EV5 Pin No Soleno...

Page 1023: ...CONTROL PEDAL At start up the pedal must have 12 V for the opera tion of the hammer When the switch is operated there must be 12 V at pin 2 Pin No Solenoid Resistance 1 12 V 7 5 F28476 2 R V 1 R V 1 F...

Page 1024: ...ITCH 1 At start up the switch must have 12 V for the oper ation of the hand hammer When the switch is operated there must be 12 V at pin 1 Pin No Solenoid Resistance 1 12 V 7 5 F28479 1 C B1 5 C B1 F2...

Page 1025: ...he switch is operated there must be 12 V at pin 5 REVERSING BUZZER Activated by 12 V at key start when reverse gear is selected With reverse travel selected there must be 12 V at pin connector Resista...

Page 1026: ...VEL GAUGE The gauge indicating the fuel level is located in the side instrument cluster Test procedure Approximate resistance Gauge indication Sensor resistance Full 9 Half 129 Empty 333 F28489 F28490...

Page 1027: ...LOADER ATTACHMENT CONTROLS 3 1 1 LOADER ATTACHMENT OPERATION 3 2 LOADER BUCKET SELF LEVELING 6 3 LOADER ATTACHMENT SAFETY STRUT 7 4 LOADER BUCKET REMOVAL 8 5 LOADER REMOVAL 11 SECTION 82 LOADER www m...

Page 1028: ...2 SECTION 82 LOADER www maskinisten net Copyright...

Page 1029: ...ADER BUCKET The function of the lever is identical to that of the ma chine fitted with the standard loader bucket with the addition of the clam control 1 1 LOADER ATTACHMENT OPERATION NEUTRAL AND HOLD...

Page 1030: ...ition 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 automati cally return to neutral when it is released It i...

Page 1031: ...and closing of the 4x1 loader bucket clam This control is proportional When releasing the roller 7 it automatically returns to the initial position neutral and the bucket remains in the position where...

Page 1032: ...n the roll back position until the bucket is in the level digging posi tion at which time the indicator on the rod of the buck et self levelling linkage will pass in front of the sensor which de energ...

Page 1033: ...tachment Stop the engine and remove the starter switch key Remove the split pins 1 and the safety strut 2 from the arm Put the split pins back in place Place the strut 2 on the cylinder rod and fasten...

Page 1034: ...t 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...

Page 1035: ...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 inte...

Page 1036: ...t be securely retained in their proper storage position using the pins and split pins provided for this purpose If forks are not cor rectly secured they can cause serious injury 4 2 REPLACING LOADER B...

Page 1037: ...ulic pressure Remove the safety rings 2 and the pins and then drive out the pins 1 Lower the lift cylinders carefully onto the chassis Remove the snap rings 3 and drive out the pins 4 Lower the arms o...

Page 1038: ...Support loader using a suitable sling Remove the safety ring and pins and then pull out the pin 8 Remove the loader from the machine INSTALLATION Installation is removal procedure in reverse www maski...

Page 1039: ...HMENT HYDRAULIC CONTROLS 15 4 REMOVAL AND INSTALLATION 17 4 1 CENTER PIVOT BACKHOE ATTACHMENT DISASSEMBLY 17 4 2 BACKHOE ATTACHMENT DISASSEMBLY SIDESHIFT 20 4 3 BACKHOE BUCKET REMOVAL 23 4 4 BUCKET TE...

Page 1040: ...2 SECTION 84 BACKHOE www maskinisten net Copyright...

Page 1041: ...machine On sideshift machines the backhoe is attached to a carriage hydraulically clamped to the machine frame This allows the operator to reposition the carriage on the frame and to adjust the posit...

Page 1042: ...he mechanical control models is controlled using two main control levers Three types of control pattern for two levers 8 and 9 systems are available as shown on the following pages A four levers deale...

Page 1043: ...h other boom dipper and bucket movements The telescopic dipper on the manually controlled models is controlled by a pedal 12 located in the rear part of the cab The telescopic dipper on pilot control...

Page 1044: ...tion 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...

Page 1045: ...SECTION 84 BACKHOE 7 www maskinisten net Copyright...

Page 1046: ...e backhoe dipper retracts Position C the backhoe attachment swings to the left Position D the backhoe attachment swings to the right Backhoe boom and backhoe bucket right hand control lever This lever...

Page 1047: ...SECTION 84 BACKHOE 9 www maskinisten net Copyright...

Page 1048: ...boom rises Position C the backhoe attachment swings to the left Position D the backhoe attachment swings to the right Backhoe dipper and backhoe bucket right hand control lever This lever has five po...

Page 1049: ...SECTION 84 BACKHOE 11 www maskinisten net Copyright...

Page 1050: ...hen movement stopped Position C the boom rises Position D the boom lowers Lever 3 for backhoe bucket This lever has three positions Position 0 neutral hold This position enables the attachment movemen...

Page 1051: ...SECTION 84 BACKHOE 13 www maskinisten net Copyright...

Page 1052: ...atically returns to the neutral po sition 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...

Page 1053: ...to be stopped As soon as re leased it automatically returns to the neutral position 0 and the attachment remains in the position where it was when movement stopped Position E the backhoe dipper extend...

Page 1054: ...e 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 re tract the telescopic dipper As soon as the b...

Page 1055: ...e on the ground S WARNING Always support the structural members so that they will be stable and safe to work around Lower stabilizers sufficiently and however ensure that the rear tyres are in contact...

Page 1056: ...ntil bucket is firmly resting on the ground Support the backhoe using suitable stand and hoist capable of carrying 1500 Kg Turn off engine then move backhoe control levers through all operating positi...

Page 1057: ...remove the pin 6 of the swing cyl inder Repeat the operation with both swing cylinders Re move the snap ring 7 Slide out the pin 8 and by means of an hammer re move the lower pin 9 from swing bracket...

Page 1058: ...ort the structural members so that they will be stable and safe to work around Lower stabilizers sufficiently and however ensure that the rear tyres are in contact with the ground to remove the weight...

Page 1059: ...ackhoe using suitable stand and hoist capable of carrying 1500 Kg Turn off engine then move backhoe control levers through all operating positions to relieve pressure in the system Re check that backh...

Page 1060: ...cyl inder Repeat the operation with both swing cylinders Re move the snap ring 7 Slide out the pin 8 and with an hammer remove the lower pin 9 from the swing support Unscrew the screw 10 Remove the u...

Page 1061: ...ravel lever and gearshift lever in neutral position Immobilize the machine by means of the parking brake Stop the engine and remove the starter switch key Remove the tooth holder 2 using a hammer and...

Page 1062: ...support the structural members so that they will be stable and safe to work around Lower stabilizers sufficiently to remove the weight from the rear wheels IMPORTANT the rear wheels must remain in con...

Page 1063: ...elieve pressure in the system Disconnect the hoses to the dipper cylinders Z Telescopic dipper hoses Z Standard dipper hose Support the dipper cylinder unscrew and remove the screw 2 slide out the pin...

Page 1064: ...26 SECTION 84 BACKHOE Support the dipper using suitable hoist Unscrew and remove the screw 4 slide out the pin 5 and care fully lower dipper to the ground www maskinisten net Copyright...

Page 1065: ...n the area around the pads Inspect each upper guide pad and if the chamfered edge 1 on the corner of the pads is no longer visible the pads have worn beyond their limit and must be replaced If pads do...

Page 1066: ...adjustment apply a coat of Dry Moly coat grease to the slide rails of the dipper NOTE when all shims have been removed the guide pads must be replaced REPLACEMENT OF GUIDE PADS To replace the guide pa...

Page 1067: ...remove the weight from the rear wheels Attach suitable hoist to top of inner section of dipper and position boom so that dipper is hanging vertical ly Disconnect the hose connections to the bucket an...

Page 1068: ...30 SECTION 84 BACKHOE NOTES www maskinisten net Copyright...

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