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SECTION 55 - ELECTRICAL SYSTEM

COMPONENTS AND CONNECTORS

NAME

DESCRIPTION

Right speaker (optional)

Left speaker (optional)

A23

EGS

A53

Radio (optional)

A106

Engine control unit

Air filter pressure switch

Fuel level sensor

B24

Accelerator knob

B25

Foot accelerator

B26

Bucket sensor

B30

Parking brake

B66

Oil temperature switch

B69

A/C pressure switch

B74

Transmission oil pressure switch

B97

Rear axle sensor

B98

Front axle sensor

B107

Water in fuel sensor

B129

Brake oil level sensor

E15

Rotating beacon

E16

Rotating beacon

E17

Warning lamp for intake

E18

Cab light

E26

Control lock warning lamp

E27

Number plate light

E28

Rear left light

E29

Rear right light

E38

Rear right work light

E40

Rear right work light (optional)

E44

Front right work light

E45

Front right work light (optional)

E46

Rear left work light (optional)

E47

Rear left work light

E50

Front left work light (optional)

E51

Front left work light

E121

Front left light/audible alarm

E133

Front right light

Main fuse

Power supply fuse

Third speed blower fuse

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

Battery

G67

Alternator

Reverse buzzer

H32

Audible alarm

HA2

Horn

K14

Transmission relay

K102

Relay for start signal from the control unit

K103

Start relay

K104

Starter motor relay

K105

A/C relay

Steering unit

Starter motor

M39

Rear windshield wiper motor

M41

Blower motor (optional)

M49

Front pump

M56

Front windshield wiper motor

M57

Rear windshield wiper motor

M64

A/C compressor

4WD switch

Hydraulic speed control switch

Drive switch

Attachment switch

S15

Start switch

S29

Front claxon switch

S32

Stop light switch

S33

Stop light switch

S34

Left door switch

S35

Right door switch

S36

Rear hammer button

S42

Warning switch

S48

EGS switch

S130

Windshield wiper switch

S132

Steering switch

S135

Backhoe attachment travel lock switch

S136

Menu scroll switch

S137

Rear work light switch

S138

Rear pump switch

S139

Display enter switch

NAME

DESCRIPTION

Содержание 580SR

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 6: ...www maskinisten net Copyright...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 828: ...68 SECTION 50 CAB HEATING AND AIR CONDITIONING NOTES www maskinisten net Copyright...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 837: ...SECTION 55 ELECTRICAL SYSTEM 9 ENGINE LINE DIAGRAM www maskinisten net Copyright...

Страница 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...

Страница 839: ...SECTION 55 ELECTRICAL SYSTEM 11 SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Страница 840: ...12 SECTION 55 ELECTRICAL SYSTEM LIGHT LINE DIAGRAM www maskinisten net Copyright...

Страница 841: ...SECTION 55 ELECTRICAL SYSTEM 13 REAR LIGHT LINE DIAGRAM www maskinisten net Copyright...

Страница 842: ...14 SECTION 55 ELECTRICAL SYSTEM WORK LIGHT LINE DIAGRAM www maskinisten net Copyright...

Страница 843: ...SECTION 55 ELECTRICAL SYSTEM 15 WINDSHIELD WIPER WASHER LINE DIAGRAM www maskinisten net Copyright...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 852: ...24 SECTION 55 ELECTRICAL SYSTEM ENGINE LINE DIAGRAM www maskinisten net Copyright...

Страница 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...

Страница 854: ...26 SECTION 55 ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 868: ...40 SECTION 55 ELECTRICAL SYSTEM ENGINE LINE DIAGRAM www maskinisten net Copyright...

Страница 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...

Страница 870: ...42 SECTION 55 ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 886: ...58 SECTION 55 ELECTRICAL SYSTEM ENGINE LINE DIAGRAM www maskinisten net Copyright...

Страница 887: ...SECTION 55 ELECTRICAL SYSTEM 59 SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Страница 888: ...60 SECTION 55 ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Страница 889: ...SECTION 55 ELECTRICAL SYSTEM 61 LIGHT LINE DIAGRAM www maskinisten net Copyright...

Страница 890: ...62 SECTION 55 ELECTRICAL SYSTEM REAR LIGHT LINE DIAGRAM www maskinisten net Copyright...

Страница 891: ...SECTION 55 ELECTRICAL SYSTEM 63 WORK LIGHT LINE DIAGRAM www maskinisten net Copyright...

Страница 892: ...64 SECTION 55 ELECTRICAL SYSTEM WINDSHIELD WASHER WIPER LINE DIAGRAM www maskinisten net Copyright...

Страница 893: ...SECTION 55 ELECTRICAL SYSTEM 65 HEATER LINE www maskinisten net Copyright...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 901: ...SECTION 55 ELECTRICAL SYSTEM 73 ENGINE LINE DIAGRAM www maskinisten net Copyright...

Страница 902: ...74 SECTION 55 ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Страница 903: ...SECTION 55 ELECTRICAL SYSTEM 75 SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Страница 904: ...76 SECTION 55 ELECTRICAL SYSTEM LIGHT LINE DIAGRAM www maskinisten net Copyright...

Страница 905: ...SECTION 55 ELECTRICAL SYSTEM 77 REAR LIGHT LINE DIAGRAM www maskinisten net Copyright...

Страница 906: ...78 SECTION 55 ELECTRICAL SYSTEM WORK LIGHT LINE DIAGRAM www maskinisten net Copyright...

Страница 907: ...SECTION 55 ELECTRICAL SYSTEM 79 WINDSHIELD WASHER WIPER LINE DIAGRAM www maskinisten net Copyright...

Страница 908: ...80 SECTION 55 ELECTRICAL SYSTEM HEATER LINE www maskinisten net Copyright...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 916: ...88 SECTION 55 ELECTRICAL SYSTEM ENGINE LINE DIAGRAM www maskinisten net Copyright...

Страница 917: ...SECTION 55 ELECTRICAL SYSTEM 89 SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Страница 918: ...90 SECTION 55 ELECTRICAL SYSTEM SOLENOID VALVE LINE DIAGRAM www maskinisten net Copyright...

Страница 919: ...SECTION 55 ELECTRICAL SYSTEM 91 LIGHT LINE DIAGRAM www maskinisten net Copyright...

Страница 920: ...92 SECTION 55 ELECTRICAL SYSTEM REAR LIGHT LINE DIAGRAM www maskinisten net Copyright...

Страница 921: ...SECTION 55 ELECTRICAL SYSTEM 93 WORK LIGHT LINE DIAGRAM www maskinisten net Copyright...

Страница 922: ...94 SECTION 55 ELECTRICAL SYSTEM WINDSHIELD WASHER WIPER LINE DIAGRAM www maskinisten net Copyright...

Страница 923: ...SECTION 55 ELECTRICAL SYSTEM 95 HEATER LINE www maskinisten net Copyright...

Страница 924: ...96 SECTION 55 ELECTRICAL SYSTEM STEERING LINE DIAGRAM www maskinisten net Copyright...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 967: ...SECTION 55 ELECTRICAL SYSTEM 139 www maskinisten net Copyright...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1028: ...2 SECTION 82 LOADER www maskinisten net Copyright...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1040: ...2 SECTION 84 BACKHOE www maskinisten net Copyright...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1045: ...SECTION 84 BACKHOE 7 www maskinisten net Copyright...

Страница 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...

Страница 1047: ...SECTION 84 BACKHOE 9 www maskinisten net Copyright...

Страница 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...

Страница 1049: ...SECTION 84 BACKHOE 11 www maskinisten net Copyright...

Страница 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...

Страница 1051: ...SECTION 84 BACKHOE 13 www maskinisten net Copyright...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 1068: ...30 SECTION 84 BACKHOE NOTES www maskinisten net Copyright...

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Case 580SR, Руководство по обслуживанию

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